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FH451V-FH480V-FH500V-FH531V-FH541V-FH580V

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1. Valve Seat Cutter Holder Bar 57001 1128 ST5711288T Valve Seat Cutter 32 633 57001 1199 Oil Filter Wrench 57001 1249 ST5711998T ST5712498T Valve Seat Cutter Holder 46 57001 1360 ST571360ST www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 11 Periodic Maintenance Procedures Fuel System NOTE OHigh and low idle speeds may vary depending on the equipment on which the engine is used Refer to the equipment specification Low Idle Speed Adjustment e Disconnect all possible external loads from the engine e Start and warm up the engine thoroughly A WARNING Always keep your hands clear of the moving parts e Move the throttle lever at a 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 e For FH601V FH641V FH661V FH680V FH721V model adjust the low idle speed screw C with Phillips Head Screwdriver D until the engine idles at specified speed Low Idle Speed Carburetor idle rpm 1 450 rpm e Release the throttle lever and adjust the low idle speed set screw A on the control plate to obtain the specified governor low idle speed Low Idle Speed Governor idle rpm 1 550 rpm KC05043BS1
2. High Idle Speed Adjustment NOTE OHigh idle speed adjustment should be made after the low idle speed adjustment is performed CAUTION Do not adjust high idle speed with the air cleaner removed e Start and warm up the engine thoroughly www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 12 PERIODIC MAINTENANCE Periodic Maintenance Procedures A WARNING Always keep your hands clear of the moving parts e Move the throttle lever at a dash to the high idle position and match the lever hole position with the panel hole by inserting 6 mm dia pin or bolt A e Loosen two M6 control panel mounting bolts B enough to move the control panel assembly e Carefully move the control panel assembly right side C up or down to obtain the specified high idle speed High Idle Speed 3 600 rpm e Tighten the M6 Mounting bolts Torque Control Panel Mounting Bolts 5 9 N m 0 60 kgf m 52 in Ib e Remove the 6 mm dia pin or bolt e Check the high idle speed and readjust the high idle speed if necessary CAUTION Be sure to make the low idle speed and high idle speed respectively correspond to those of the equipment www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 13 Periodic Maintenance Procedures Fuel System Cleanliness Inspection A WARNING Gasoline is extremely flammable and can be ex plosiv
3. e Remove the foam element and the paper element e Clean the foam element A in a bath of detergent and water and dry the element by air thoroughly before in stallation www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Clean the paper element A by tapping it gently on a flat surface to remove dust If the element is very dirty re place it with a new one CAUTION Do not use compressed air to clean the paper ele ment Do not oil the paper element or the foam ele ment FH601V FH641V FH661V FH680V FH721V Models e Remove the foam and paper elements see Air Cleaner Element Removal e Clean the foam element A in a bath of detergent and water and let the element air dry thoroughly e Clean the paper element B by tapping it gently on a flat surface to remove dust If the element is very dirty re place it with a new one Heavy Duty Air Cleaner Type For FH541V and FH580V Models This air cleaner element is not recommended to be cleaned and the air cleaner element should be replaced with a new one at the maintenance time as shown in the maintenance chart NOTE OOperating in dusty condition may require more frequent maintenance than above e Remove the element see Element Removal in the Fuel System chapter e Replace the element A every 250 hrs CAUTION Do not wash air cleaner element Do
4. www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures Valve Clearance Adjustment e Since valve repairs change the valve clearance adjust the valve clearance as specified e Assemble the cylinder head and install the cylinder head assembly on the block see Cylinder Head Installation e Turn the crankshaft in proper direction until the piston is at the TDC of the compression stroke as described above e Loosen the lock screws A and the valve clearance ad justing nuts B e Insert a 0 10 mm 0 04 in thickness gauge C between the rocker arm and valve stem Tighten the adjusting nut until the thickness gauge begins to bind between the rocker arm and valve stem end Sweep the thickness gauge during this adjustment Valve Clearance when cold Inlet Exhaust 0 10 0 15 mm 0 004 0 006 in e Holding the adjusting nut with a spanner tighten the lock screw to the specified torque Torque Valve Clearance Lock Screws 6 9 N m 0 70 kgf m 61 in Ib e Do not overtighten the valve clearance lock screws e After the valve clearance adjustment measure the valve clearance again Readjust the valve clearance if neces sary Valve Seat Inspection e Remove the valve see Valve Mechanism Removal Instal lation e Inspect the valve seats for damage x lf the seats are warped or distorted beyond recondition ing replace the
5. e Check the O ring B at the oil drain plug for damage Re place the O ring with a new one if it is damaged x lf the oil drain plug joint is removed tighten it Torque Oil Drain Plug Joint Plastic 17 N m 1 7 kgf m 12 0 ft lb Oil Drain Plug Joint Metal 39 N m 4 0 kgf m 29 ft lb e Install the oil drain plug with the O ring and tighten it Torque Oil Drain Plug Plastic 6 9 N m 0 70 kgf m 61 in Ib Oil Drain Plug Metal ft lb 20 N m 2 0 kgf m 14 5 e Remove the oil filler cap and pour in the specified type and the amount of oil Engine Oil Grade SF SG SH SJ or SL Class Viscosity SAE40 SAE30 SAE10W 30 SAE10W 40 or SAE5W 20 Capacity When the oil filter is not removed 1 5 L 1 6 US qt When the oil filter is removed 1 7 L 1 8 US qt except FH721V 1 8 L 1 9 US qt FH721V e Check the O ring A on the oil filler cap for damage Re place the O ring with a new one if it is damaged When checking the oil level do not turn oil filler cap on threads NOTE OSome increase in oil consumption may be expected when a multi grade engine oil 10W 30 10W 40 5W 20 is used Check the oil level more frequently than recom mended interval lt Ambient Temperature _ gt 20 C 10 C SE oe 40 C L EI 4 F 14 F 32 F pled 68 F ie 104 F KFO5004BS1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 56
6. B Distance FH451V FH500V FH531V 6 mm 0 24 in B Distance FH541V FH580V O mm 0 in B Distance FH601V FH641V FH661V FH680V FH721V 12 mm 0 47 in Kc10014BS1 e Clean the mating surfaces of the carburetor and inlet man ifolds and install the new gaskets A and insulator B in the sequence as shown in the figure e Install the inlet manifold e Tighten the mounting bolts Torque Inlet Manifold Mounting Bolts 5 9 N m 0 60 kgf m 52 in Ib e Install and tighten the band A around the manifold B and the lead C and or the harness D OPosition the lead and or the harness on top ofthe manifold as shown in the figure e Cut the excessive band off e Install the other removed parts in the reverse order of the disassembly www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 33 Inlet Manifold Inlet Manifold Inspection e Inspect the inlet manifold for cracks or porous casting e Cracks not visible to the eye may be detected by using a metal crack detection system Visual color check com monly found at automotive parts stores lf a crack is present in the inlet manifold replace it with a new one e Inspect the gasket surfaces for burns and nicks www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 34 FUEL SYSTEM Fuel Pump Fuel Filter The fuel pump cannot be disassembled
7. TO BREATHER TUBE AND GYLINDER HEAD Ka08018BW5 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 10 CAMSHAFT CRANKSHAFT Breather Heavy Duty Air Cleaner Type for FH601V FH641V FH680V FH721V OIL lt FRESH AIR 2 BLOW BY GAS e GN EE m Fell eS ot d ali WHO S79 i ed FROM BREATHER TUBE TO BREATHER TUBE AND GYLINDER HEAD x ZB BEI IR Ka080198W5 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 7 11 Breather Breather Element Removal FH451V 500V 531V 541V 580V e Remove the bolts A and the breather chamber cover B e Remove the element A e Check to see that the plate B is in place under the ele ment A Breather Element Installation FH451V 500V 531V 541V 580V e Apply the sealant to the mating surface A of the crankcase Le Y Sealant Kawasaki Bond Silicone Sealant 56019 120 i A e Install a new gasket and the breather chamber cover and H tighten the bolts ss Torque Breather Chamber Cover Bolts 5 9 Num 0 60 my kgf m 52 in Ib Breather Valve Inspection FH601V 641V 661V 680V 721V A e Unscrew the mounting screw A and remove the plate B and the breather valve C e Inspect the breather valve C for breakage crack or dis tortion replace it w
8. x If the inside diameter is more than the service limit re place the connecting rod with a new one Connecting Rod Small End Inside Diameter Service Limit 16 05 mm 0 632 in Piston Diameter e Measure the outside diameter A of the piston 12 5 mm 0 9 in B up from the bottom of the piston at a right angle to the direction of the piston pin hole x If the measured outside diameter is less than the service limit replace the piston with a new one Piston Diameter Model Service Limit FH451V FH500V FH531V 67 79 mm 2 669 in Pees FH541V FH580V 73 79 mm 2 905 in FH601V FH641V FH661V FH680V FH721V 74 99 mm 2 952 in Cylinder Inside Diameter e Clean and measure the cylinder inside diameter OUse a cylinder gauge to measure front to back and side to side at the points as shown in the figure x If any of the cylinder inside diameter measured value is greater than the service limit the cylinder must be bored to the next oversize and then honed see Cylinder Boring and Honing www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 22 ENGINE TOP END Cylinder Piston Cylinder Inside Diameter Model Item Standard Sery e S Limit Standard 67 98 68 00 mm 68 10 mm FH451V Cylinder 2 676 2 677 in 2 681 in FH500V S FH531V 0 5 mm Oversize 68 48 68 50 mm 68 60 mm Cylinder 2 696 2
9. Seat Cutter Operating Cares 1 This valve seat cutter is designed only for valve seat re pair Do not use the valve seat cutter for other purpose 2 Do not drop or hit the valve seat cutter or the diamond particles may fall off 3 Be sure 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 thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter represent the B following 1 Cutter number selected from 1 to 12 32 Cutter angle A 37 5 Cutter diameter B KS8B Manufactured lot number KEO5016BS1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures Operating Procedures e Clean the seat area carefully e Recondition the valve seats with the valve seat cutters 45
10. 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 Directy and gradually open throttle valve by hand Does the revolution drop or does engine stall at a certain position Is air sucked through carburetor or inlet manifold flanges Are valve clearances of normal values Is alignment of timing gear marks correct NO NO e Loose flange nuts e Damaged gasket Replace e Compression leakage Adjust valve clearance Wrong valve timing Wrong governor linkage Correct adjustment Faulty governor spring Replace Governor assembly Check malfunction Plugged air hole in tank gt Clean cap Entry of dust and air into Clean fuel filter or fuel pipe Faulty plug insulation Replace Fouled electrodes Clean Faulty ignition coil Replace Wrong air gap Correct YES e Overrich fuel in pilot system Turn in pilot screw a NO little Plugged in carburetor Disassemble and interior clean Retighten Correct alignment of timing gear marks e Largely deviated valve Correct alignment of timing timing gear marks K102051B F www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING 10 5 Engine Troubleshooting Guide Excessive fuel consumption Is compression sufficient YES NO e High fuel level in carburetor float Adjust chamber including overfl
11. e Connect the breather tube from the crankcase to the pipe at the back of the air cleaner body e Tighten the holder plate nuts and the air cleaner body mounting screws Torque Holder Plate Nuts 5 9 N m 0 60 kgf m 52 in Ib Air Cleaner Body Mounting Screws 3 4 N m 0 35 kgf m 30 in Ib FH601V FH641V FH661V FH680V FH721V e Replace the inlet pipe gaskets with new ones e Clean the mating surfaces of the carburetor and the inlet pipe e Install the inlet pipe and solenoid valve lead e Tighten the mounting bolts and nuts Torque Inlet Pipe Mounting Bolts and Nuts 5 9 N m 0 60 kgf m 52 in Ib e Install the sleeve on the inlet pipe e Press in the sleeve A to the inlet pipe B fixing the groove C to the projection D as shown in the figure e Connect the breather tube to the pipe at the inlet pipe and clip it with a clamp www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 37 Air Cleaner Standard Type www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 38 FUEL SYSTEM Air Cleaner Heavy Duty Type Element Removal e Unhook the two retaining clamps A and remove the cap B from the air cleaner body KC06015BS1 e Remove Primary Element A Secondary Element B KCc06016BS1 For FH541V FH580V e Remove Element A KC06026BS1 Element Installation O e Slide the secondary el
12. A e Connect AC voltmeter to the stator pins B e Start the engine Run the engine at the 3 000 rpm speed e Voltage reading should be minimum 26 VAC 3 000 rpm If the AC voltage reading is less than the specification replace the stator with a new one Unregulated Stator Output MIN 26 VAC 3 000 rpm Regulator Removal e Remove Stator Coil Lead Connector A Regulator Screws B Regulator C Regulator Installation e Install the regulator and tighten the screws Torque Regulator Screws 3 4 N m 0 35 kgf m 30 in Ib www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 9 15 Charging System Regulator Resistance e Set the KAWASAKI Hand Tester selector switch to the R x 100 O position e Connect the test leads to the points shown on the chart and read the resistance O OThere are two 2 types of Regulator on FH engines as follows Without Charging Monitor Type 3 Blades NOTE OResistance value may vary with individual meters With Charging Monitor type 5 Blades 500 oo roto tote 330 Q 12KQ 14KQ co x If the resistance is not as specified replace the regulator with a new one www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 9 16 ELECTRICAL SYSTEM Ignition System This engine ignition is controlled by a solid st
13. FH531V FH541V FH580V e Pull the hooks A to outside and remove the air cleaner cover B e Remove Wing Bolt A Foam Element B Paper Element C Element Removal FH601V FH641V FH661V FH680V FH721V e Remove Air Cleaner Case Nut Air Cleaner Case Wing Nut A Foam Element B Paper Element C Element Installation e Install the element correctly on the air cleaner body e Be sure to install the paper element into the air cleaner body e Be sure to install the foam element on the paper element Element Cleaning and Inspection e Refer to the Element Cleaning and Inspection in the Pe riodic Maintenance chapter Air Cleaner Body Removal FH451V FH500V FH531V FH541V FH580V e Remove the elements see Element Removal e Remove the air cleaner body mounting screws A the holder plate nuts B and the holder plate C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 36 FUEL SYSTEM Air Cleaner Standard Type e Pull the breather tube A off the pipe at the back of the body and remove the air cleaner body B FH601V FH641V FH661V FH680V FH721V e Remove the element see Element Removal e Remove the clamp A and pull off the breather tube B e Loosen the nuts C and remove the solenoid valve lead D e Unscrew the bolts E and remove the inlet pipe F Air Cleaner Body Installation FH451V FH500V FH531V FH541V FH580V
14. If any damage of the pump is noticed replace it with a new one Fuel Pump Inspection e Check the vent hole A and the filter B for plugging or clogging x If the vent hole and the filter are plugged or clogged re move the foreign material from them Fuel Flow Test A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Disconnect the fuel pump outlet nozzle from the tube e Connect a suitable hose A to the outlet nozzle e Run the lower end of the hose into a container e Start the engine Check the fuel flow x If fuel flow is none or little replace the fuel pump with a new one Check the tubes and the fuel filter for clogging or damage Replace the clogged or damaged tubes of fuel filter with new ones Fuel Filter Inspection e Visually inspect the fuel filter A x If the filter is clear with no signs of dirt or other contami nation replacement of the fuel filter is not necessary x If the filter is dark or looks dirty replace it with a new one Also check the rest of the fuel system for contamination www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 35 Air Cleaner Standard Type Element Removal FH451V FH500V
15. The big diam ee I eter side of the float pin must face the choke value side e Assemble carburetor parts with recommended tightening torque see Exploded View 1 Limiter 2 Pilot Screw KC05041BS3 C 3 Spring 4 Spacer 5 Low Idle Speed Screw 6 7 8 9 Spring Screws Throttle Valve Throttle Shaft 10 Dust Seal 11 Choke Valve 12 Choke Shaft 13 Dust Seal 14 Solenoid Valve Electric Starter Model 15 Gasket 16 Float Bowl 17 Gasket 18 Float Pin 19 Float 20 Main Jet 21 Main Nozzle 22 Float Valve 23 Gasket 24 Screw Other than Solenoid Valve Type www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 26 FUEL SYSTEM Carburetor Carburetor Disassembly Assembly FH601V FH641V FH661V FH680V FH721V e Refer to the illustration for disassembly and assembly e There are several passage plugs Ball plugs in the car buretor body Do not remove them e Before disassembly mark the out side of choke valve and throttle valves for assembling them 1 Plug Pilot Screw 2 Pilot Screw 3 Low Idle Speed Screw 4 Spring 5 Seal 6 Collar 7 Throttle Valve 8 Screws 9 Throttle Shaft 10 Choke Valve 11 Choke Shaft 12 Seal 13 Float Valve 14 Float Pin 15 Float 16 Gasket 17 Float Bowl 18 Screw 19 Clamp 20 Plug Main Jet 21 Gasket 22 Main Jet L 23 Main Jet R 24 Slow Jet 25 Drain Screw 26
16. 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 Recoil Starter see Recoil Starter Installation e For Electric Starter model note the following procedure Olnstall the bracket A so that the notch B inserts into the slot in the flywheel OPut the washer C OTighten the flywheel bolt D Torque Flywheel Bolt 56 N m 5 7 kgf m 41 ft lb Olnstall the fan housing and tighten the bolts Torque Fan Housing Bolts 5 9 N m 0 60 kgf m 52 in Ib www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 9 13 Charging System Olnstall Spacer A Screen B OPosition three sets C of screen notches around the fan blades OTighten the screen bolts D Torque Screen Bolts 5 9 N m 0 60 kgf m 52 in Ib KHO7O10BS2 C Charging System Operational Inspection e Check the battery condition NOTE OAlways check the battery condition before judging other parts of the charging system The battery must be fully charged for accurate charging system tests e Warm up the engine to bring the components up to their normal operating temperatures e Measure regulated output voltage at various engine speeds OConnect a voltmeter across the battery terminals The readings should show nearly battery voltage when the engine speed is low and as the engine speed rises the readings should also rise B
17. 0 0945 in C 43 0 mm MAX 1 693 in MAX D 37 95 38 05 mm 1 4941 1 4980 in e The crankpin surface should be concentric and parallel to each other within 0 006 mm 0 0002 in full indicator reading e Finish the crankpin surface with a super finishing stone www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 STARTER SYSTEM 8 1 Starter System Table of Contents EXPO WEE 8 2 Specifications EE 8 4 Starter EE 8 5 Starter Motor HRemoval 8 5 Starter Motor Installation caben tis 8 5 Starter Motor DisassemblY coco vedas recent eand ES ste acneeseeeeuaeanecte 8 5 Starter leie EE 8 6 Starter Motor Brush Inspection ccoccccccccnccccnncnnnnnnnnnnnnnnnnnnnnnnnnnnnononnnnnnnnnnnnnnnnnnnnnnninnnss 8 6 Brush Spring Inspection 8 6 Armature INSPECION EE 8 6 Yoke ASsembly Ee e EE 8 8 Pinion Clutch Inspection occcccccncccnncnnncnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninnnss 8 8 Recoil Starter Hemoval crie e ee eie ea ea a E REN 8 8 Recoil Starter Installation cecccecceeccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeneeeeeeeeseeeseeeeeeess 8 8 Recoil Starter Disassembly i ccoo e 8 9 Recoll tante Assembly EE 8 10 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 2 STARTER SYSTEM Exploded View KHO2007BW5S www mymowerparts com For Kawasaki Disc
18. 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 13 Exploded View FH451V FH500V FH531V T1 5 9 N m 0 60 kgfm 52 in lb T2 2 0 N m 0 20 kgfm 17 in lb T3 7 8 N m 0 80 kgf m 69 in lb FH541V FH580V T1 5 9 N m 0 60 kgf m 52 in lb T2 2 0 N m 0 20 kgfm 17 in lb T3 7 8 N m 0 80 kgf m 69 in lb FH601V FH641V FH661V FH680V FH721V T1 5 9 N m 0 60 kgf m 52 in Ib T2 2 0 N m 0 20 kgfm 17 in lb T3 7 8 N m 0 80 kgf m 69 in Ib A Separate Choke Type B Associate Choke Type O Apply engine oil 1 Fuel Tube for FH680V Late Model 2 Fuel Tube for FH680V Early Model www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 14 FUEL SYSTEM Specifications Float Level Idle Speed 1 Low Idle Speed High Idle Speed Air Cleaner Standard Model Type Pre cleaner Second stage cleaner Heavy Duty Model Type Cleaner Pre cleaner Second stage cleaner Fuel Fuel Requirement Fuel Pump Type Governor Type 1 550 r min rpm 3 600 r min rpm Dual stage filtration system Foam element Paper element Pulse diaphragm pump Float parallel to carburetor body Unleaded regular grade gasoline Flyweight all speed governor Standard FH601V FH641V D sm GE FH531V FH541V FH580V FH661V FH680V FH721V Carburetor Specifications Make Type MIKUNI B24T1 Walbro LMF Nikki 621266 Throttle Bore Diameter 24 m
19. 697 in 2 701 in Standard 73 98 74 00 mm 74 10 mm FH541V Cylinder 2 912 2 913 in 2 917 in FH580V 0 5 mm Oversize 74 48 74 50 mm 74 60 mm Cylinder 2 932 2 933 in 2 937 in FH601V Standard 75 18 75 20 mm 75 28 mm FH641V Cylinder 2 960 2 961 in 2 964 in FH661V 0 5 mm Oversize pape 2 979 2 980 in 2 983 in Cylinder Inside Diameter Out Round Standard 0 01 mm 0 004 in Service Limit 0 056 mm 0 0022 in Cylinder Boring and Honing Always resize to exactly 0 5 mm 0 02 in over the stan dard bore size If this is done accurately the stock oversize rings and pis ton will fit perfectly and proper clearance will be maintained Resize the cylinder bore by a reliable repair shop or by using a drill press and a honing tool Use the stone recommended by the hone manufactures to produce correct cylinder wall finish Machine bore first the inside diameters are shown in the table Boring Inside Diameter Inside Diameter 2 696 in Honing Inside Diameter 2 932 in FH451V FH541V FH601V FH500V FH580V FH641V Oversize FH531V FH661V FH680V FH721V 68 46 68 48 74 46 74 48 75 65 75 68 0 50 mm mm 2 695 mm 2 931 mm 2 978 2 979 in Inside Diameter www mymowerparts com FH451V FH541V FH601V 3 FH500V FH580V FH641V Oversize FH531V FH661V FH680V FH721V 68 48 68 50 74 48 74 50 75 68
20. Attach the compression gauge assembly firmly into one plug hole Special Tools Compression Gauge 20 kgf cm 57001 221 A Compression Gauge Adapter M14 x 1 25 57001 1159 e Ground the spark plugs to the engine A WARNING To avoid fire do not ground the spark plugs in prox imity to the plug holes Keep the plugs as far away as possible from the plug holes e Open the throttle fully Run the engine by pulling the re coil starter grip several times until the compression gauge stops rising Read the highest compression value Re coil starter model Cylinder Compression MIN 390 kPa 57 psi e Open the throttle fully Run the engine by turning the en gine switch key several times until the compression gauge stops rising Read the highest compression value Elec tric starter model Cylinder Compression MIN 390 kPa 57 psi e Repeat the measurement on the other cylinder 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 worn valve guides and or worn piston oil rings may cause rapid carbon accumul
21. Cylinder Layout 90 V Twin Bore x Stroke 68 mm x 68 mm 74 mm x 68 mm 75 2 mm x 76 mm 2 68 in x 2 68 in 2 91 in x 2 68 in 2 96 in x 2 99 in Displacement 494 mL 30 1 cu in 585 mL 35 6 cu in 675 mL 41 19 cu in Direction of Rotation Counterclockwise facing the PTO shaft Compression Release Automatic compression release Low Idle Speed 1 550 rpm High Idle Speed 3 600 rpm Ignition System Transistorized fly wheel magneto RFI Per Canada and U S A requirements Starting System Electric starter and or recoil starter Charging System 12 V 13 amps with regulator Item FH541V FH580V FH721V Spark Plug CHAMPION RCJ8Y NGK BPR4ES Carburetor Float type fixed main jet Float type fixed main jet two barrel Fuel Pump Diaphragm type pulse pump Air Cleaner Dual stage element dry type Heavy duty type Governor Flyweight all speed governor Lubrication System Pressure feed by positive displacement pump Oil Filter Cartridge type full flow filter Oil Pressure Switch ON OFF switch Option Oil Capacity when 1 8 L 1 9 US qt 1 9L engine is completely 2 0 US qt dry Cooling System Forced air cooling by fan Dimensions 425 mm x 359 mm x 425 mm x 359 mm x LxWxH 324 mm 324 mm 458 mm x 430 mm x 381 mm Electric Starter Model 16 7 in x 14 1 in x 16 7 in x 14 1 in x 18 0 in x 16 9 in x 15 0 in 12 8 in 12 8 in Recoil Starter Model 425 mm x 359 mm x 425 mm x 359 mm
22. Ib Inspection e Measure the inside diameter A of the PTO shaft bearing on the crankcase cover at several points This bearing is not replaceable Replace the crankcase cover if with a new one the inside diameter is greater than the service limit PTO Shaft Bearing Inside Diameter C moa erica Limit FH451V 500V 531V 35 15 mm 1 384 in FH541V 580V 35 15 mm 1 384 in FH601V 641V 661V 680V 721V 40 15 mm 1 581 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 7 7 Crankcase e Measure the inside diameter A of the crankshaft journal bearing on the crankcase at several points This bearing is not replaceable Replace the crankcase with a new one if the inside diameter is greater than the service limit Crankshaft Journal Bearing Inside Diameter eel Service Limit FH451V 500V 531V 35 15 mm 1 384 in FH541V 580V 35 15 mm 1 384 in FH601V 641V 661V 680V 721V 40 15 mm 1 581 in Cleaning e Remove Camshaft and Tappets see Camshaft Tappet Removal Crankshaft see Crankshaft Removal e Clean up the crankcase and cover with a high flash point solvent and blow out any foreign particles that may be in the pockets inside of the crankcase with compressed air A WARNING Clean the crankcase and cover in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the dange
23. Parts Call 606 678 9623 or 606 561 4983 6 2 LUBRICATION SYSTEM Exploded View www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LUBRICATION SYSTEM 6 3 Exploded View FH451V FH500V FH531V T1 3 9 N m 0 40 kgfm 35 in Ib T2 6 9 N m 0 70 kgf m 61 in Ib Plastic T3 9 8 N m 1 0 kgf m 87 in 1b T4 20 Nm 2 0 kgf m 14 5 ft lb Metal T5 39 Nm 4 0 kgf m 29 ft lb Metal T6 17 N m 1 7 kgf m 12 0 ft Ib Plastic T7 See the text T8 5 9 N m 0 60 kgf m 52 in Ib FH541V FH580V T1 3 9 N m 0 40 kgf m 35 in Ib T2 6 9 N m 0 70 kgf m 61 in Ib Plastic T3 9 8 N m 1 0 kgf m 87 in 1b T4 20 N m 2 0 kgf m 14 5 ft lb Metal T5 39 N m 4 0 kgf m 29 ft lb Metal T6 17 N m 1 7 kgf m 12 0 ft lb Plastic T7 See the text T8 5 9 N m 0 60 kgf m 52 in Ib FH601V FH641V FH661V FH680V FH721V T1 3 9 N m 0 40 kgf m 35 in Ib T2 6 9 N m 0 70 kgf m 61 in Ib Plastic T3 9 8 N m 1 0 kgf m 87 in Ib T4 20 N m 2 0 kgf m 14 5 ft lb Metal T5 39 N m 4 0 kgf m 29 ft lb Metal T6 17 N m 1 7 kgf m 12 0 ft lb Plastic T7 See the text T8 5 9 N m 0 60 kgf m 52 in Ib T9 44 N m 4 5 kgf m 33 ft lb FH721V Before FH500V A50316 FH531V A07510 Model FH451V FH500V FH531V FH451V FH580V Model FH601V FH641V FH661V FH680V FH721V Model Apply engine oil Apply silicone sealant YO UOW gt www mymowerpa
24. Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 67 79 57001 1097 e Insert the piston and the connecting rod so that the arrow match mark A on the piston crown faces the flywheel side B www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 18 ENGINE TOP END Cylinder Piston CAUTION The connecting rod and the connecting rod big end cap are machined at the factory in the assembled state so they must be replaced together as a set e Apply engine oil to the inner surface A of the connecting rod big end B and caps C e Install the connecting rod big end caps on their original position on each connecting rod big ends e Apply a thin layer of engine oil to the thread D and seat ing surface E of the cap bolts e Tighten the cap bolts Torque FH451V 500V 531V Connecting Rod Big End Cap Bolts 5 9 N m 0 60 kgf m 52 in Ib FH541V 580V Connecting Rod Big End Cap Bolts 9 8 N m 1 0 kgf m 87 in Ib FH601V 641V 661V 680V 721V Connecting Rod Big End Cap Bolts For M7 x P1 0 screw thread spec 21 N m 2 1 kgf m 15 in Ib Connecting Rod Big End Cap Bolts For M6 x P1 0 screw thread spec 9 8 N m 1 0 kgf m 87 in Ib e Install Camshaft see Camshaft Crankshaft chapter Crankcase Cover see Camshaft Crankshaft chapter Piston Cylinder Seizure e In case of seizure remove the piston e Visually inspect the
25. Spring 27 Gasket 28 Solenoid Valve www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 Carburetor FUEL SYSTEM 3 27 Carburetor Disassembly Assembly FH680V and FH721V Late Models e Refer to the illustration for disassembly and assembly e There are several passage plugs Ball plugs in the car buretor body Do not remove them e Before disassembly mark the out side of choke valve and throttle valves for assembling them Plug Pilot Screw Pilot Screw Gasket Cover Plate Screws Low Idle Speed Screw Spring Seal Collar Throttle Valve Screws Throttle Shaft Choke Valve Choke Shaft Seal Main Jet L Main Jet R O rings Gasket O ring Spacer Pin Float Valve Float O ring Gasket Screws Gasket Solenoid Valve Drain Screw Spring KCO5131BS83 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 28 FUEL SYSTEM Carburetor e Replace the pilot screw A with a new one if necessary in accordance with the following procedure ORemove the pilot screw plug B material Stainless steel as follows Punch a hole in the plug and pry it out with an awl or other suitable tool OTurn in the pilot screw and count the number of turns until it seats fully but not tightly then remove the screw This is to set the screw to its original position when
26. Switch 9 8 1 0 87 in lb SS Oil Passage Plug 3 9 0 40 35 in lb Oil Pump Cover Plate Mounting Bolts 5 9 0 60 52 in lb Oil Filter in the text Oil Cooler Mounting Joint FH721V 44 4 5 33 Camshaft Crankshaft Crankcase Cover Bolts 25 2 6 19 0 S Breather Chamber Cover Bolts 5 9 0 60 52 in lb Electrical System Stator Coil Screws 3 4 0 35 30 in lb Flywheel Bolt 56 5 7 41 Fan Housing Bolts 5 9 0 60 52 in lb Screen Bolts 5 9 0 60 52 in lb Regulator Screws 3 4 0 35 30 in lb Ignition Coil Bolts Studs 7 8 0 80 69 in lb Ignition Coil Bolts Bolts 5 9 0 60 52 in lb Starter Motor Mounting Bolts 15 1 5 11 Recoil Starter Mounting Nuts z Recoil Starter Retainer Screw Spark Plugs 22 2 2 16 The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners Threads dia Torque mm N m kgf m ft lb 4 2 0 0 20 17 in lb 5 3 4 0 35 30 in Ib 6 5 9 0 60 52 in Ib 8 15 1 5 11 www mymowerparts com Specifications For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 9 Item Standard Fuel System Idle Speed 1 Low Idle Speed High Idle Speed Air Cleaner Type Pre cleaner Second stage cleaner Type Clea
27. assembling OTurn in the new pilot screw A fully but not tightly then back it out the same number of turns counted during dis assembly Olnstall a new pilot screw plug B in the pilot screw hole by pressing with the rod C and apply a small amount of a bonding agent D around the plug to fix the plug e Install the choke valve and throttle valve on the shaft as the outside mark of them facing outside and apply a small amount of a bonding agent to the valve screw threads CAUTION Do not apply too much bonding agent to the valve Screws themselves may be fixed e Drive the float pin into the carburetor body The big side of the float pin must face the throttle shaft lever side e The fuel inlet valve seat is pressed into the carburetor body and is not replacable e Assemble carburetor parts with specified tightening torque see Exploded View www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 Carburetor FUEL SYSTEM 3 29 Carburetor Cleaning A WARNING Clean the carburetor in a well ventilated area and take care that there is no sparks or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean the carburetors CAUTION Do not use compressed air on an assembled carbu retor or the floats may be crushed by the pressure Rem
28. cam lobes e Pull the camshaft A out of the crankcase e Remove the tappets A and mark them to reinstall in their original positions during assembly Camshaft Tappet Installation e Apply engine oil to the followings Tappet Journal Camshaft Journal Cam Lobe Surface Camshaft Gear e Align the punch marks A on the crankshaft gear and camshaft gear e Install the shim B on the camshaft www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 7 13 Camshaft Tappet Camshaft Disassembly e Remove the governor assembly see Fuel System chap ter e Remove Spring A ODo not remove the ACR automatic compression release weight B Camshaft Assembly e Install the governor assembly see Fuel System chapter e After assembling the camshaft check the following items OThe governor plate A must move freely OWhile shaking the camshaft check if the ACR weight B swings smoothly Camshaft Inspection e Check the camshaft gear A for pitting fatigue cracks burrs or any evidence of improper tooth contact Replace the shaft with a new one if necessary e Check the top of the cam lobes B for wear burrs or un even contact Replace the shaft with a new one if necessary Camshaft Bearing Journal Wear e Measure the height of each cam lobe x lf the cam height is less than the service limit for either lobe replace the camshaft with a new one Ca
29. cylinder head with a new one 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 lapping tool e Pull the valve out and check the seating pattern on the valve head It must be the correct width A and even all the way around NOTE Good Too Wide OThe valve stem and guide must be in good condition or this check will not be valid x If the valve seating pattern is not correct repair the seat Too N Valve Seating Surface Width STD Cre Le FH451V FH500V FH531V FH541V FH580V Inlet Exhaust 0 6 0 9 mm 0 024 0 035 in FH601V FH641V FH661V FH680V FH721V Inlet 0 8 1 4 mm 0 03 0 05 in Exhaust 1 1 1 6 mm 0 04 0 06 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Valve Seat Repair e Follow the manufacture s instructions for use of valve seat cutters Special Tools Inlet Valve Valve Seat Cutter 45 35 57001 1116 Valve Seat Cutter 32 633 57001 1199 Exhaust Valve Valve Seat Cutter 45 p30 57001 1187 Valve Seat Cutter 32 p30 57001 1120 Valve Seat Cutter Holder d 57001 1360 Valve Seat Cutter Holder Bar 57001 1128 x If the manufacture s instructions are not available use the following procedure
30. discolored at the detected area e If a crack is present in the cylinder head replace it with a new one e Inspect the mating surface for burrs or nicks e Clean and inspect the rocker arm where it touches the push rod and the valve stem x If the contact points A are worn or damaged replace the rocker arm with a new one Valve Clearance Inspection NOTE OCheck the valve clearance when the engine is cold at room temperature e Remove the rocker cover see Cylinder Head Removal e Place the piston at the top dead center TDC of the com pression stroke by turning the crankshaft clockwise facing the flywheel No 1 Cylinder OThe left projection A on the flywheel is faced with the right leg B on the 1 ignition coil C as shown in the figure OCheck the inlet and exhaust valves are closed completely if they are not closed turn the flywheel one turn 360 clockwise and face the left projection with the right leg again No 2 Cylinder OThe left projection A on the flywheel is faced with the right leg B on the 2 ignition coil C as shown in the figure Follow No 1 Cylinder alignment e 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 no correct adjust it Valve Clearance when cold Inlet Exhaust 0 10 0 15 mm 0 004 0 006 in KEO5014BS1 KEO5015BS1
31. engine Repair or replace STARTER ROTATES BUT CAN NOT CRANK ENGINE Does pinion mesh with ring No gt Worn pinion or ring gear Replace gear e Wrong starter alignment Correct YES e Faulty pinion clutch Replace e Faulty engine Repair or replace STARTER DOES NOT STOP IN ENGINE SWITCH OFF Can stop starter by engine No e Faulty engine switch Repair or replace switch OFF e Faulty solenoid switch Replace YES e Faulty pinion or ring gear Repair or replace e Wrong starter alignment Correct e Faulty pinion return mechanism Repair or replace KI03009B_F www mymowerparts com 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 2078 01 Printed in Japan www mymowerparts com
32. not oil air cleaner element Do not use pressurized air to clean air cleaner element FH601V FH641V FH661V FH680V FH721V Models Air cleaner elements are notrecommended to be cleaned and each air cleaner element should be replaced with new ones at the maintenance time as shown in the maintenance chart NOTE OOperating in dusty condition may require more frequent maintenance than above e Remove the elements see Element Removal in the Fuel System chapter e Replace the primary element A every 250 hrs www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures e Replace the secondary element A with a new one if dirty when primary element is checked e Replace the secondary element every 500 hrs CAUTION Do not wash air cleaner elements Do not oil air cleaner elements Do not use pressurized air to clean air cleaner elements Housing Cap and Body Inspection e Clean the housing with detergent and water and dry the housing thoroughly e Check the housing for deformation or other damage OSeal the housing well and permit only filtered air to reach the carburetor x If the housing is damaged replace the housing with a new one e Check that no foreign material obstructs the air passage Engine Top End Cylinder Head Cleaning and Inspection e Scrape the carbon deposits from the cylinder head and
33. of choke Plugged air cleaner Too high fuel level in float bowl Worn piston piston rings Stuck piston rings Worn cylinder bore Insufficient cylinder head tightening Faulty contact of valve seat Plunge up by valve Warped cylinder head Broken valve spring Stuck valve Burned head gasket Replace Correct Replace Add Clean Clean Clean Remove the plug and turn the crankshaft without loading Clean Adjust Replace Clean or replace Bore or replace Retighten Lap Adjust valve clearance Replace Clean or replace Replace KI02049B_F www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING 10 3 Engine Troubleshooting Guide Engine power loss YES e Too much or too little oil in Correct Is engine overheated NO crankcase Excessive engine load Decrease load e Carburetor is not properly Adjust adjusted e Carbon deposit in combustion Clean chamber e Clogged cooling system Clean e Damaged cooling fan Replace Is the ignition spark NO e Wrong spark plug Replace normal YES e Faulty ignition coil Replace e Wrong air gap Adjust gap Is lubricating NO e Too much or too little oil in Correct condition normal YES crankcase e Excessively contaminated Change lubricating oil e Defective oil filter Replace 6 Faulty relief valve Replace Faulty oil pump Replace e Clogged oil system Cl
34. on the connecting rod Keep parts together as a set e Remove the piston pin snap ring A with needle nose pliers B e Remove the piston by pushing the piston pin A to the direction from which the snap ring was removed www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 16 ENGINE TOP END Cylinder Piston e Remove the top and second rings with piston ring pliers Special Tool Piston Ring Pliers 57001 115 e f the special tool is not available carefully spread the ring opening with your thumbs then push up to the opposite side of the ring A to remove it e Remove the 3 piece oil ring with your thumbs in the same manner Piston Installation e Install the expander A in the piston oil ring groove so that the expander ends B touch together never overlap them e Install the upper and lower steel rails There is no UP or Down to the rails They can be installed either way e Do not mix up the top and second rings e Install the top and second rings as shown in the figure The rings should turn freely in the grooves Piston Head A Top Ring for FH451V 500V 531V 541V 580V B Second Ring for FH451V 500V 531V 541V 580V C Top Ring for FH601V 641V 661V 680V 721V D Second Ring for FH601V 641V 661V 680V 721V E e Align the piston and rings with the piston ring end gap as shown in the figure Arrow Match Marks A Top Ring
35. or turning it over 7 High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent com monly available in North America is Standard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent 8 Gasket O Ring Do not reuse a gasket or O ring once it has been in service The mating surfaces around the gasket should be free of foreign material and perfectly smooth to avoid oil or compression leaks 9 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 Seal Blue 10 Press A part installed using a press or driver such as a journal should first be coated with oil on its outer or inner circumference so that it will go into place smoothly 11 Ball Bearing When installing a ball bearing the bearing race which is affected by friction should be pushed by a suitable driver This prevents severe stress on the balls and races and prevents races and balls from being dented Press a ball bearing until it stops at the stop in the hole or on the shaft 12 Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally dam age
36. so that the marks A face out OPack some amount of high temperature grease B into the space between the seal lip C and the dust lip D OPress in the new oil seal using a press or suitable tools until it is flush or below the flange surface E ODo not damage the seal lips F PTO Side 1 2 mm 0 04 0 08 in Flywheel Side 0 1 mm 0 0 04 in KG04013BS1 e When replacing the oil seal A of the governor shaft note the following Olnstall the oil seal into the crankcase cover B after insert ing the governor shaft in the crankcase cover and so that the marks C face out OThe depth D is 0 1 mm 0 0 04 in e When installing the governor shaft and plate in the crankcase cover see Fuel System chapter www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 6 CAMSHAFT CRANKSHAFT Crankcase e Check to see that the crankcase dowel pins A are in place on the crankcase e Install the gasket on the crankcase e Install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence shown in the figure Torque Crankcase Cover Bolts 25 N m 2 6 kgf m 19 0 ft lb ODo not turn one screw down completely before the others as it may cause the crankcase cover to warp e For FH601V 641V 661V 680V 721V model tightening sequence is as shown in the figure Torque Crankcase Cover Bolts 25 N m 2 6 kgf m 19 0 ft
37. the battery positive terminal to the chassis ground OTroubles may involve one or all items in some cases Never replace a defective part without determining what CAUSED the failure If the failure was occurred by an other item or some other items repair and or replace the item s Or the failure may happen again OMake sure all connectors in the circuit are clean and tight and examine the leads for signs of burning fraying etc Poor leads and bad connections will affect electrical sys tem operation OMeasure the coil and the winding resistance when the parts are cold at room temperature OElectrical connectors Connectors A GP07000281 Connectors B GPO070003S1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 9 10 ELECTRICAL SYSTEM Charging System Flywheel Stator Coil Removal e Remove Recoil Starter see Recoil Starter Removal e Loosen the fan housing bolts A and remove the fan housing B e Remove Ignition Coils see Ignition Coil Removal Stud Bolts A e Hold the flywheel with a suitable tool remove the flywheel bolt and the washer e For Electric Starter model note the following procedure ORemove Nuts A and Guard B Bolt C and Screen D Spacer E OLoosen the fan housing bolts A and remove the fan housing B www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 498
38. the exhaust port with a suitable tool A e To avoid gouging use scrapers that material will not dam age the cylinder head and the exhaust pipe e Clean the head in a bath of high flash point solvent and dry it with compressed air A WARNING Clean the cylinder head in a well ventilated area and take care that there are no sparks or flame any where near the working area this includes any ap pliance with a pilot light Do not use gasoline or a low flash point solvent to clean the cylinder head A fire or explosion could result e Lay a straight edge A across the mating surface of the cylinder head at several different points and measure the warp by inserting a thickness gauge B between the straight edge and the cylinder head x lf the warp exceeds the service limit repair the mating surface Replace the cylinder head with a new one if the mating surface is badly damaged or warped Cylinder Head Warp Service Limit 0 05 mm 0 002 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Check the cylinder head for cracks or other damage e Cracks not visible to the eye may be detected by coating the suspected area with mixture of 25 kerosene and 75 light engine oil e Wipe the area dry and immediately apply a coating of zinc oxide dissolved in wood alcohol If a crack is present the coating will become
39. their arms while pulling off the carburetor www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 22 FUEL SYSTEM Carburetor e For FH541V FH580V model see the figure e For FH601V FH641V FH661V FH680V FH721V model note the following OUnhook the throttle link spring B at the link clip F with a long nose plier OUnhook the link clip F and remove the throttle link rod D and choke link rods E at the ends of their arms while pulling off the carburetor Carburetor Installation e Clean the mating surfaces of the carburetor and inlet man ifold and fit the new gaskets e Install the inlet manifold the new gaskets the insulator the carburetor the new gasket and the inlet pipe in the sequence as shown e For FH451V FH500V FH531 model Inlet Manifold A Gaskets B Insulator C Carburetor D Gasket E Stud Bolt F e For FH541V FH580V model Inlet Manifold A Gaskets B Insulator C Carburetor D Gasket E Stud Bolt F KC05128BS1 KC05129BS1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 23 Carburetor e For FH601V FH641V FH661V FH680V FH721V model Inlet Manifold A Gaskets B Insulator C Carburetor D Gasket E KC05130BS1 e Install the air cleaner see Air Cleaner Body Installation e Take care not to bend the throttle link rod an
40. to the condition of them replace them with new ones Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure 20 Specifications Specification terms are defined as follows Standards show dimensions or performances which brand new parts or systems have Service Limits indicate the usable limits If the measurement shows excessive wear or 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 Electric Starter Model FH500V Recoil Starter Model FH500V Cylinder Number Designation No 1 Cylinder is the left hand cylinder viewed from the air cleaner No 2 Cylinder is the right hand cylinder viewed from the air cleaner www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 5 Model Identification Electric Starter Model FH580V www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 1 6 GENERAL INFORMATION Model Identification Heavy Duty Air Cleaner Type KB03006BW9 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 7 General Specifications FH451V FH500V FH601V FH641V FH531V FH661V FH680V Type Forced air cooled vertical shaft OHV 4 stroke gasoline engine
41. with a new one if necessary e Turn the throttle and choke shafts to check that the throttle and choke butterfly valves move smoothly x If the valves do not move smoothly replace the carburetor body and or throttle shaft and choke shaft assembly with new ones e Check the gasket on the carburetor body x If the gasket is not in good condition replace it with a new one e Check the other parts of the carburetor for any wear or damage Replace the part with a new one if necessary e Clean and check the float level as follows CAUTION Do not push down on the float during float level checking e With the float A assembly installed onto the carburetor body B hold the carburetor upside down at eye level Gently support the float with a finger and bring it down slowly so that the float arm tab C just touches the float valve D The float lower surface E should be parallel with the carburetor body mating surfaces F x If the float position is not correct replace the float with a new one 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 pushed in and released x If either the needle or the seat is worn or damaged re place the float assembly and carburetor body as a set with a new one Good Bad www mymowerparts com For Kawasaki Discount Parts Call 606 678
42. x 361 mm 361 mm e 16 7 in x 14 1 in x 16 7 in x 14 1 in x 14 2 in 14 2 in Dry Weight Electric Starter Model 34 kg 75 lbs 34 kg 75 Ibs 40 5 kg 89 3 lbs 41 2 kg Recoil Starter Model 32 kg 71 Ibs 32 kg 71 lbs 90 8 Ibs Specifications are 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 Et agoe a dete lt bai 2 2 Torque and Locking Ag ari alain dette A ce ash tn estan A a aa Ai epoha 2 4 Specifications EE 2 9 Special TOO EE 2 10 Periodic Maintenance PrOCedures ococnnoninnoncnnccinnnn sacras 2 11 A In 2 11 Low Idle Speed Adjustment evo coo ies 2 11 High Idle Speed Adjustment a tons cela tenable asa Ed 2 11 Fuel System Cleanliness Inspection 222 cccceteeeeeseeceeeeeeeeeeesneceeeeeeeteneneeesececeeneneentes 2 13 Element Cleaning and Inspection ees isis Jaden a iba 2 13 Housing Cap and Body INnSpeCuons oriol atari 2 15 Engine TOD ENG nta te ia O ee ee 2 15 Cylinder Head Cleaning and Inspection cccceeeseesseeeeneeeeeeeenenseeeeceeeeeeeneneeesenenees 2 15 Valve Clearance Inspection A 2 16 Valve Clearance AUS IM eege tetdanist sateen eii dep ENANA eet bats aeedetadentatdans 2 17 Valve Seat Inspection 2 0 ccc cceccceccceccee
43. 1 4983 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Oil Filter Replacement e Drain the engine oil see Oil Change e Remove the oil filter A with the oil filter wrench B or strap wrench 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 e Replace the oil filter A with a new one e Apply light film of engine oil to the seal B e Install the oil filter OTurn the filter until the seal contacts mounting surface C of the engine Then turn the filter BY HAND S 3 4 turn more e Run the engine at slow idle speed for 2 minutes OWhile running the engine check for oil leaks around it e Stop the engine and check the oil level see Oil Level Inspection Oil Cooler Cleaning e Clean dirt off the outside fins with brush or with com pressed air Electrical System Spark Plug Cleaning and Inspection e Carefully pull the plug cap from the spark plug and re move the spark plug x lf the plug is oily or has carbon built up on it clean the plug using a high flash point solvent and a wire brush or other suitable tools x If the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug with a new one Use the standard spark plug or its equivalent Insulator A Center Electrode B Plug Gap C Side Electrode D Sp
44. 23 or 606 561 4983 5 6 ENGINE TOP END Specifications Item Service Limit FH451V FH500V FH531V FH541V FH580V Cylinder Head Cylinder Compression MIN 390 kPa 57 psi MIN Cylinder Head Warp 0 05 mm 0 002 in Valves Valve Head Thickness Inlet Exhaust 0 35 mm 0 014 in Valve Stem Runout Inlet Exhaust 0 05 mm 0 002 in Valve Stem Diameter Inlet 5 95 mm 0 0234 in Exhaust 5 93 mm 0 0233 in Valve Clearance Standard Inlet Exhaust 0 10 0 15 mm 0 004 0 006 in Valve Seating Surface Angle Standard Inlet Exhaust 45 Valve Seating Surface Width Standard Inlet Exhaust 0 6 0 9 mm 0 024 0 035 in Valve Guide Inside Diameter Inlet Exhaust 6 08 mm 0 239 in Valve Spring Free Length Inlet Exhaust 31 0 mm 1 22 in Rocker Arm Push Rod Runout Inlet Exhaust Cylinder Piston Piston Diameter Piston Ring Groove Clearance Top Second Piston Ring Thickness Top Second Piston Ring End Gap Top Second Oil Piston Pin Outside Diameter Piston Pin Hole Inside Diameter Connecting Rod Small End Inside Diameter Cylinder Inside Diameter Standard Cylinder 0 50 mm Oversize Cylinder Inside Diameter Out Round 0 056 mm 0 0022 in 0 5 mm 0 02 in 67 79 mm 2 669 in 0 15 mm 0 006 in 0 12 mm 0 005 in 1 40 mm 0 055 in 0 70 mm 0 028 in 0 78 mm 0 031 in 1 05 mm 0 041 in 15 96 mm 0 628 in 1
45. 3 ELECTRICAL SYSTEM 9 11 Charging System ORemove Ignition Coil see Ignition Coil Removal Stud Bolts A OHold the flywheel with a suitable tool remove the flywheel bolt and the washer Zu a e Using a suitable flywheel puller A remove the flywheel B CAUTION Always use flywheel puller e Remove Woodruff Key A Stator Coil Lead Connector B Stator Coil Screw C Stator Coil D Flywheel Stator Coil Installation e Install the stator coil and tighten the screws Torque Stator Coil Screws 3 4 N m 0 35 kgf m 30 in Ib e Using a cleaning fluid clean off any oil or dirt on the fol lowing portions and dry them with a clean cloth Crankshaft Tapered Portion A Flywheel Tapered Portion B e Fit the Woodruff key C securely in the slot in the crank shaft before installing the flywheel www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 9 12 ELECTRICAL SYSTEM Charging System e Install the fan A so that two positioning bosses B fit around flywheel ignition magnet C e Install the plate D so that the notch E inserts into the slot in the flywheel e Install the screen A so that the projections B fit into the recess C of the fan e Install the pulley A so that the tabs of the plate fit into holes B in the pulley e Put the washer C as shown in the figure e Tighten the flywheel bolt D Torque Flywheel Bolt 56 N m 5 7 kgf m 41 ft lb
46. 3 or 606 561 4983 ENGINE TOP END 5 3 Exploded View FH451V FH500V FH531V T1 5 9 N m 0 60 kgf m 52 in lb T2 6 9 N m 0 70 kgf m 61 in lb T3 25 N m 2 6 kgf m 19 5 ft lb T4 28 N m 2 8 kgf m 20 ft lb T5 22 N m 2 2 kgf m 16 ft lb FH541V FH580V T1 9 8 N m 1 0 kgf m 87 in lb T2 6 9 N m 0 70 kgf m 61 in lb T3 25 N m 2 6 kgf m 19 5 ft lb T4 28 N m 2 8 kgf m 20 ft lb T5 22 N m 2 2 kgfm 16 ft lb FH601V FH641V FH661V FH680V FH721V T1 21 N m 2 1 kgfm 15 ft lb For M7 x P1 0 screw thread spec T1 9 8 N m 1 0 kgf m 87 in Ib For M6 x P1 0 screw thread spec T2 6 9 N m 0 70 kgf m 61 in Ib T3 25 N m 2 6 kgf m 19 5 ft lb T4 28 N m 2 8 kgf m 20 ft Ib T5 22 N m 2 25 kgf m 16 ft lb G Apply grease O Apply engine oil S Follow the specified tightening sequence www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 4 ENGINE TOP END Exploded View KE 2025BW5 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 5 Exploded View FH451V FH500V FH531V T2 15 N m 1 5 kgfm 11 0 ft Ib FH541V FH580V T2 15 N m 1 5 kgfm 11 0 ft lb FH601V FH641V FH661V FH680V FH721V T2 15 N m 1 5 kgfm 11 0 ft Ib 1 Muffler Comp for Late Models 2 Muffler Comp for Early Models www mymowerparts com For Kawasaki Discount Parts Call 606 678 96
47. 32 and lap the valves e Check the seats for good contact all the way around with 45 A machinist s dye e Measure the seat width A If it is greater than the STD width reface the seating surface e 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 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 contact on the valve seat with the 45 cutter to remove any possible burrs at the edge of the seat e After resurfacing the seat inspect for even valve seating OApply a machinis
48. 6 08 mm 0 633 in 16 05 mm 0 632 in 68 10 mm 2 681 in 68 60 mm 2 701 in 73 79 mm 2 905 in 7 ee A 1 7 74 10 mm 2 917 in 74 60 mm 2 937 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 7 Specifications Service Limit FH601V FH641V FH661V FH680V FH721V Cylinder Head Cylinder Compression MIN Cylinder Head Warp 390 kPa 57 psi MIN 0 05 mm 0 002 in Valves Valve Head Thickness Inlet Exhaust Valve Stem Runout Inlet Exhaust Valve Stem Diameter Inlet Exhaust Valve Clearance Inlet Exhaust Valve Seating Surface Angle Inlet Exhaust Valve Seating Surface Width Inlet Exhaust Valve Guide Inside Diameter Inlet Exhaust Valve Spring Free Length Inlet Exhaust Rocker Arm Push Rod Runout Inlet Exhaust Cylinder Piston Piston Diameter Piston Ring Groove Clearance Top Second Piston Ring Thickness Top Second Piston Ring End Gap Top Second Oil Piston Pin Outside Diameter Piston Pin Hole Inside Diameter Connecting Rod Small End Inside Diameter Cylinder Inside Diameter Standard Cylinder 0 50 mm Oversize 0 35 mm 0 014 in 0 05 mm 0 002 in 5 95 mm 0 0234 in 5 93 mm 0 0233 in Standard 0 10 0 15 mm 0 004 0 006 in Standard 45 Standard 0 8 1 4 mm 0 03 0 06 in 1 1 1 6 mm 0 04 0 06 in 6 08 mm 0 239 in 31 0 mm 1 22
49. 61 4983 CAMSHAFT CRANKSHAFT 7 15 Crankshaft Connecting Rod Connecting Rod Removal e Remove Piston see Engine Top End Chapter Connecting Rod Installation e Install Piston see Engine Top End chapter Crankshaft Removal e Set the engine on a clean surface while parts are re moved e Drain the oil see Lubrication System chapter e Remove Flywheel see Electrical System chapter Camshaft see Camshaft Tappet Removal Connecting Rod and Piston Assembly see Engine Top End chapter e Pull the crankshaft A out of the crankcase Using a wooden or plastic mallet gently tap the crankcase to loosen the crankshaft Crankshaft Installation e Clean up the crankshaft and crankcase thoroughly espe cially at the bearing contact surfaces e Pack some amount of high temperature grease into the oil seal on the crankcase e Apply engine oil to the journal and bearing e Carefully insert the crankshaft flywheel end into the main bearing and the oil seal in the crankcase Cleaning Inspection e After removing clean the crankshaft and the connecting rods with a high flash point solvent and dry them with compressed air e Inspect the teeth of the crankshaft gear for pitting fatigue cracks burrs and any evidence of improper tooth contact Replace the gear with a new one if necessary e Inspect the crankshaft and connecting rods especially at the bearing surfaces for wear scratches any evidence of improper contact or o
50. 75 70 0 50 mm mm 2 696 mm 2 932 mm 2 979 2 697 in 2 933 in 2 980 in For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 23 Cylinder Piston Change to a honing stone for finishing the final inside di ameter should be as shown in the table e Be sure to use correct finishing stone and the stone should not be worn e Clean the cylinder at the top and bottom of the cylinder to remove burns and pieces of the base and head gasket e Anchor the cylinder block on the drill press table before honing e Align the center of the cylinder bore to the press center Set the press to operate from 200 to 250 rpm e Connect the drive shaft to the hone and set the stop on the drill press so the hone can only extend 20 to 25 mm 3 4 to 1 0 in above the top or below the bottom of the cylinder liner e Rotate the adjusting nut knob on the hone until the stones contact snugly against the narrowest point of the cylinder wall Do not Force e Turn the honing stone by hand If you cannot turn it the stone is too tight Loosen the hone until you can turn it by hand e Be sure that the cylinder and the hone are centered and aligned with the drive shaft and the drill spindle e Pour honing oil inside of the cylinder during the honing operation Start the drill press Move the hone up and down in the cylinder approximately 20 cycles per minute e Check the diameter of the cylinder bore regularl
51. 78 9623 or 606 561 4983 3 8 FUEL SYSTEM Exploded View FH601V FH641V FH661V FH680V FH721V Kc02048BW5 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 Exploded View FUEL SYSTEM 3 9 FH601V FH641V FH661V FH680V FH721V Pilot Screw Pilot Air Jet Main Air Jet Main Jet Pilot Jet Solenoid Valve Out Vent Tube Before 2003 5 Product model 1 0 N m 0 10 kgf m 9 in Ib 3 9 N m 0 40 kgf m 35 in Ib 2 0 N m 0 20 kgfm 18 in Ib 19 N m 1 9 kgf m 14 ftlb 20 N m 2 0 kgfm 15 ft lb 5 9 N m 0 60 kgfm 52 in lb www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 10 FUEL SYSTEM Exploded View Heavy Duty Air Cleaner Type www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 11 Exploded View Heavy Duty Air Cleaner Type 1 Main Jet 2 Pilot Screw 3 Solenoid Valve R Replacement Parts T1 1 0 N m 0 10 kgf m 9 in Ib T2 3 9 N m 0 40 kgf m 35 in Ib T3 2 0 Nm 0 20 kgf m 18 in lb T4 2 5 N m 0 25 kgf m 22 in lb T5 6 9 N m 0 70 kgf m 61 in lb T6 9 8 N m 1 0 kgf m 87 in Ib T7 5 9 N m 0 60 kgf m 52 in Ib www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 12 FUEL SYSTEM Exploded View Kc020518W5 C www mymowerparts com For Kawasaki Discount Parts Call
52. 78 9623 or 606 561 4983 6 14 LUBRICATION SYSTEM Oil Pump Relief Valve x If cleaning does not solve the problem replace the relief valve parts with new ones x If necessary put the ball in position and lightly tap the ball with a suitable tool to form a perfect seat e Measure the 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 with a new one Relief Valve Spring Free Length Service Limit 19 50 mm 0 77 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LUBRICATION SYSTEM 6 15 Oil Screen Oil Screen Removal e Remove the crankcase cover see Camshaft Crankcase chapter e Unscrew the mounting bolts A and remove the oil pump parts assembly e Remove the oil screen B e Before FH500 A50136 FH531 A07510 model the oil screen is as shown in the figure Oil Screen Installation e Clean the oil screen thoroughly whenever it is removed for any reason e Insert the oil screen A in position and install the oil pump parts assembly see Oil Pump Relief Valve Installation e Before FH500 A50136 FH531 A07510 model the oil screen is as shown in the figure www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 16 LUBRICATION SYSTEM Oil Screen Cleaning and Inspection e Clean the oil screen with high flash point solvent and re move any part
53. 9623 or 606 561 4983 FUEL SYSTEM 3 31 Carburetor e Inspect the tapered portion A of the pilot screw B for wear or damage x If the pilot screw is worn or damaged on the taper portion replace it with a new one e Check the spring condition replace it with a new one if necessary e For FH601V FH641V FH661V FH680V FH721V model the pilot screw is as shown in the figure Fuel Shut Off Solenoid Valve Test Electric Starter Model e Unscrew the fuel shut off valve and remove the valve e Connecta 12 VDC source to the solenoid as shown in the figure x lf the actuated solenoid plunger Needle Valve does not pop out when the Test Voltage is applied replace it with a new one NOTE Olf necessary push the plunger slightly for the plunger to withdraw www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 32 FUEL SYSTEM Inlet Manifold Inlet Manifold Removal e Remove Air Cleaner see Air Cleaner Body Removal Engine Upper Cover e Cut off the band A and release the harness and or lead from the inlet manifold e Unscrew the manifold mounting bolts B e Then lifting up the inlet manifold middle section A then pull out the inlet manifold from the carburetor B as shown in the figure Inlet Manifold Installation e Replace the inlet manifold gaskets with new ones e Clean the mating surfaces of the cylinders and inlet man ifolds and fit new gaskets A
54. Connecting R d Removal seraa anaana eaaa a cut bind A DAA A nc acacia 7 15 Connecting Rod Installation aaa cis 7 15 CrankshattRemovall acta Eed aa 7 15 Crankshaft Installation oooooonononnconoccnnncnonnnnnnnnnonononnnnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnninnninnnss 7 15 e Un e Met en EE 7 15 Connecting Rod Bend E 7 16 Connecting Rod Big End Crankpin Width Wear cocccccnonococcccncciconcnanancnononnnnnnnanannnnnnnos 7 16 Connecting Rod Big End Bearing Crankpin West 7 17 Crankshatt RUMOUE ua A A e daa 7 17 Crankshaft Main Journal Wear sssssssseessseeeseesseesseesrrerrrerttrttrrttrrtttrtttrttrrttrrttrrrrrttertrteettent 7 18 Crank pili RESIZING EE 7 18 www mymowerparts com For Kawasaki Discount 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 FH451V FH500V FH531V T1 5 9 N m 0 60 kgf m 52 in Ib T2 25 Nm 2 6 kgf m 19 0 ft lb T3 See Engine Top End chapter FH541V FH580V T1 5 9 N m 0 60 kgf m 52 in Ib T2 25 Nm 2 6 kgf m 19 0 ft lb T3 See Engine Top End chapter FH601V FH641V FH661V FH680V FH721V T1 5 9 N m 0 60 kgf m 52 in Ib T2 25 N m 2 6 kgf m 19 0 ft lb T3 See Engine Top End chapter G Apply grease O Apply engine oil S Follow the specific tightening sequence SS Apply silic
55. EM 6 9 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 returns to the crankcase A pressure relief valve is used between the oil pump and oil filter to relieve excessive oil pressure by returning excessive oil to the crankcase see Oil Flow Chart Oil Pressure Measurement e Remove the oil pressure switch or oil passage plug from the crankcase e Install an appropriately sized oil pressure gauge adapter A and oil pressure gauge B e Run the engine and warm up thoroughly e Run the engine at high idle speed and read the oil pres sure gauge e Stop the engine e Remove the oil pressure gauge and the adapter e Apply silicone sealant to the threads of the pressure switch and tighten it or tighten the oil passage plug Sealant Kawasaki Bond Silicone Sealant 56019 120 Torque Oil Pressure Switch 9 8 N m 1 0 kgf m 87 in Ib Oil Passage Plug 3 9 N m 0 40 kgf m 35 in Ib x If the measured oil pressure is below the specification inspect the oil pump and the relief valve x If the oil pump and the relief valve are not at fault inspect the rest of the lubrication system Oil Pressure 414 to 690 kPa 60 to 100 psi Measurement Condit
56. End Gap Upper Steel Rail End Gap B 30 45 C Second Ring End Gap Lower Steel Rail End Gap D e Apply engine oil to the piston pins e Assemble the pistons onto the connecting rods as follow No 1 cylinder piston align the arrow match mark on the piston crown with the K mark on the connecting rod Both marks must face the PTO side No 2 cylinder piston align the arrow match mark on the piston head with K Mark on the connecting rod to face the magnet side No 1 cylinder Piston A No 2 cylinder Piston B Arrow Match Marks C K Mark D Opposite K Mark E GE160606S1 GE160130S1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 17 Cylinder Piston e When installing a piston pin snap ring compress it only enough to install it Do not compress the piston pin snap ring too hard 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 on the edge of the piston pin hole CAUTION Do not reuse the snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Apply engine oil to the piston skirt and the cylinder bore x Using the piston ring compressor grip A and the belt B lightly tap the top of the piston with a plastic mallet C to insert the piston and connecting rod into the cylinder Special Tools
57. FH451V FH500V FH531V Choke Valve Screw 0 7 0 07 6 in Ib Throttle Valve Screws 1 0 0 1 9 in lb Pilot Jet 1 7 0 17 15 in lb Main Jet 0 7 0 07 6 in lb Main Air Jet 0 7 0 07 6 in lb Main Nozzle 2 0 0 20 17 in lb Pilot Air Jet 0 7 0 07 6 in lb Drain Screw 1 3 0 13 11 ml Ground Lead Screw Carburetor Side 3 4 0 35 30 in lb Fuel Shut Off Solenoid Valve 6 9 0 70 61 in lb Float Bowl Mounting Bolt 8 8 0 90 78 in lb Carburetor FH541V FH580V Throttle Valve Screws 0 7 0 07 6 ml L Main Jet 2 3 0 23 20 in lb Fuel Shut off Solenoid Valve 4 5 0 46 40 in lb Float Chamber Mounting Screw 4 5 0 46 40 in lb Governor Arm Clamp Nut 7 8 0 80 69 in lb Governor Shaft Plate Screws 2 0 0 20 18 in lb Holder Plate Nuts Air Cleaner Carburetor 5 9 0 60 52 in lb Mounting Inlet Manifold Mounting Bolts 5 9 0 60 52 in lb Air Cleaner Body Mounting Screws 3 4 0 35 30 in lb Air Cleaner Body Bracket Bolts Heavy Duty 5 9 0 60 52 in lb Air Cleaner Type Air Cleaner Body Bracket Nuts Heavy Duty 9 8 1 0 87 in lb Air Cleaner Type Control Panel Mounting Bolts 5 9 0 60 52 in lb Cooling System Engine Shroud Bolt M8 15 1 5 11 Engine Shroud Bolts M6 5 9 0 60 52 in lb Plug Bolt Engine Shroud 5 9 0 60 52 in lb Plug Screw Engine Shroud 3 4 0 35 30 in lb www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 5 Torque and Locking Agent FH451V FH500V FH531V FH541V FH580V Torque Fastener Rema
58. For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FH451V FH500V FH531V FH541V FH580V FH601V e FH641V FH661V FH680V Kawasaki FH721V ANA NES 4 Stroke Air Cooled V Twin 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 Starter System Electrical System mmh 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 FH451V FH500V FH531V FH541V FH580V FH601V FH641V FH661V FH680V FH721V Kawasaki 4 Stroke Air Cooled V Twin Gasoline Engine Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mech
59. IAL ONS it AA A A of Hata tector ee A oo 9 4 Wiring Diagram FH451V FH500V FH531V FH541V FERHDOONT cece eee ee eeeeeeeeeeeeeeees 9 5 Wiring Diagram FH451V FH500V FHS31V eee ee eeeennee eter ee eeeeeaaaeeeeeeeeeeeeeeeneeeeeeeeeees 9 6 Wiring Diagram FH601V FH641V FH661V FH680V FH721V eneee 9 8 Precautions ceags cade se disk RAKUN AEA EIKER TEAKE orei ia 9 9 Eileen EE 9 10 Flywheel Stator Coil Removal eneen e eese res reenn r nsnrnnn nnne nnne nnsa nnne nenen nnne ennnen 9 10 Flywheel Stator Coil Installaton ccc cccccccecceecceecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseneeeeeeeess 9 11 Charging System Operational Inspection eee ceeeeeeeee eee eeeeeeeeeeeeeeeeeeeeeneaaeeeeeeeeeeeeeaaaaes 9 13 Stator Goil Resistant Eaire mar AN E RN E A E TA E A ii 9 14 Unregulated Stator OUP Ut EE 9 14 Regulator REMOVAL A Oa ie E Me ida eto ee ead ase eb 9 14 Regulator Install avon a abe Saha daeh renarena aa aA APEI ea PAALA E dv Aana aAa Ease weeds 9 14 Regulator Resistance os ccccctaase ecciicevetan ees id iia 9 15 Ignition SST EE 9 16 Igntior Col Romo luis il arepas hiba 9 17 Ignition Col Installation ET 9 17 Ignition Coil Inspection ii e 9 18 Spark Plug Cleaning and Inspection TEE 9 18 Spark Plug Gap Inspection occcccccccnccnnncnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnneninnnss 9 18 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 9 2 ELECTRICAL SYSTE
60. M Exploded View www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 9 3 Exploded View FH451V FH500V FH531V T1 3 9 N m 0 40 kgf m 35 in lb T2 5 9 N m 0 60 kgf m 52 in lb T3 7 8 N m 0 80 kgf m 69 in lb T4 22 N m 2 2 kgf m 16 ft lb T5 56 N m 5 7 kgf m 41 ft lb FH541V FH580V T1 3 9 N m 0 40 kgf m 35 in Ib T2 5 9 N m 0 60 kgf m 52 in lb T3 7 8 N m 0 80 kgf m 69 in Ib T4 22 N m 2 2 kgf m 16 ft lb T5 56 N m 5 7 kgf m 41 ft lb FH601V FH641V FH661V FH680V FH721V T1 3 9 N m 0 40 kgf m 35 in Ib T2 5 9 N m 0 60 kgf m 52 in lb T3 7 8 N m 0 80 kgf m 69 in lb T4 22 N m 2 2 kgf m 16 ft lb T5 56 N m 5 7 kgf m 41 ft lb Flywheel Recoil Starter Model Flywheel Electric Starter Model Charging Coil Voltage Regulator Stud Before 2002 4 Product Model Stud On and after 2002 5 Product Model Oak GO A www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 9 4 ELECTRICAL SYSTEM Specifications Standard Item FH451V 500V 531V FH601V 641V Service Limit 541V 580V 661V 680V 721V Charging System Regulated Output Voltage 14 1 VDC 15 V DC Alternator Stator Coil Resistance in the text EE Unregulated Stator Output 28 4 V AC 3 000 rpm 26 V AC 3 000 rpm Regulator Resistance in the text Ignition System Ignition Coil Pri
61. a tion in the combustion chamber This may be indicated by white exhaust smoke x If the cylinder compression is lower than the MIN check the following 1 Gas leakage around the cylinder head replace the damaged gasket with a new one and check the cylinder head warp Condition of the valve seating Valve clearance Piston cylinder wear piston seizure Piston ring piston ring groove www mymowerparts com MAD For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 10 ENGINE TOP END Cylinder Head Cylinder Head Assembly Removal e Remove Air Cleaner and Carburetor see Fuel System chapter Muffler see Muffler Exhaust Pipe Removal Inlet Manifold see Fuel System chapter Spark Plug e Unscrew the rocker cover mounting bolts A and remove the cover B and the gasket e When removing the 1 2 cylinder head set each pis ton at the top dead center T D C A of the compression stroke e Loosen the cylinder head bolts 1 4 turn in the sequence as shown in the figure 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 to reinstall in their original position during assembly Cylinder Head Assembly Installation e Clean the mating surfaces of the cylinder heads and cylin ders e Install the push rods in their original p
62. all the air cleaner body bracket with the bolts to the specified torque Torque Air Cleaner Body Bracket Bolts 5 9 N m 0 60 kgf m 52 in Ib e Set the air cleaner body A onto the bracket so that the air inlet duct B is facing upward e Install the inlet hose C and position the clamps D pinch heads as shown e Install the air cleaner body clamp bolt A as shown and tighten it Collar B Spring C Nut D e Install the air cleaner elements see Element Installation e Install the cap as shown For FH541V FH580V Air Cleaner Body A Air Inlet Duct B Inlet Hose C Clamps D KCOGO19BS2 KC06018BS1 KC06029BS2 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 41 Air Cleaner Heavy Duty Type Air Cleaner Body Clamp Bolt A Collar B Spring C Nut D 15 E KC06030BS1 Housing Cap and Body Inspection e Refer to the Housing Cap and Body Inspection in the Periodic Maintenance chapter 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 COOLING SYSTEM 4 1 Cooling System Table of Contents EXPO WEE 4 2 Cooling Fara asi A e toa 4 4 lenke Fan tie EE 4 4 Cooling Fan Installation 4 4 Cooling Fan IMS BSCUON E 4 4 Screen Clearance Adjustment cccccceccccen
63. ameter is greater than the service limit re place the connecting rod with a new one Connecting Rod Big End Inside Diameter mode Service Limit FH451V 500V 531V 35 055 mm 1 380 in FH541V 580V 38 055 mm 1 498 in FH601V 641V 661V 680V 721V 38 055 mm 1 498 in e Measure the crankpin outside diameter A OUse a micrometer to measure several points around the crankpin circumference x If the crankpin diameter is less than the service limit re place the crankshaft with a new one Crankpin Outside Diameter Model Service Limit FH451V 500V 531V 34 94 mm 1 3756 in FH541V 580V 37 94 mm 1 494 in FH601V 641V 661V 680V 721V 37 94 mm 1 494 in Crankshaft Runout e Measure the crankshaft runout OSet the crankshaft in a flywheel alignment jig or on V blocks gauge OSet a dial gauge against both bearing journals OTurn the crankshaft slowly to measure the runout The difference between the highest and the lowest dial gauge readings TIR is the amount of runout x If the measurement exceeds the service limit replace the crankshaft with a new one Crankshaft Runout Service Limit 0 05 mm 0 002 in TIR www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 18 CAMSHAFT CRANKSHAFT Crankshaft Connecting Rod Crankshaft Main Journal Wear e Measure both main journals at several points around the journal circumference x If the jou
64. anical photocopying recording or otherwise without the prior written permission of Quality Division Consumer Products amp Machinery Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring 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 O 2006 Kawasaki Heavy Industries Ltd 1 Edition 1 Mar 31 2006 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 C DC F ft 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 rpm TDC TIR DEE pound s meter s minute s newton s pascal s horsepower pound s per square inch revolutio
65. ark Plug Gap Inspection e Measure the gap with a wire type thickness gauge x If the gap is not correct carefully bend the side electrode with a suitable tool to obtain the correct gap Spark Plug Gap Standard 0 75 mm 0 030 in DEER Z NS FO Ni PATADA PAS U LLL NN KK ZO Se SSSSS 222 SINS NO KZ ll Pe E GP10012381 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 WEE 3 2 eelere TEE 3 14 Governor LINK Mecha iS Mii op deed RNS 3 15 Control Panel Assembly Removal ccccccccsecseeceeeeeeeeeeseecneeeeeeeeeeennesensceeeseeeeneesennaetene 3 15 Control Panel Assembly Installation acsi3rnatees tenis sanesusdstnaaceuseanacurs shane snub timatieed meguitndarvacees 3 15 Governor Arm Remo 3 15 Governor Arm Installatori ssion r a a a e a Ea 3 16 Governor Assembly Removal cocina 3 16 Governor Assembly Installation tt ancl doa aa dene 3 17 Governor Assembly Inspection cancion dido 3 17 Governor Shaft Removal rai arinaa a earar 3 17 Governor Shaft Installation oonnooncoccccnnnncnnnnnnnnonononononnnonnnnnononnnnnnnnnnonnnonnnonnncnnnoss 3 17 Carburetor nten a oa a ege a e a a A N 3 18 Fuel ANCA ie De 3 18 Fuel Shut Off Solenoid Valve Electric Starter Model 3 20 Low dle Speed Adjustments as oi anata Shares 3 20 High Idl
66. ate ignition assembly and requires no periodic main tenance except for the spark plugs The system consists of the following Inductive Ignition Assemblies Permanent Magnet Flywheel Spark Plugs Stop Switch Co Core Lamination D1 Diode L1 Primary Coil L2 Secondary Coil Q1 Transistor B Base C Collector E Emitter R1 Control Resistor TS1 Trigger Sensor SP Spark Plug M SW Stop Switch Flywheel F Magnet F ZE a M CW Rotation N North Pole S South Pole Ignition Theory of Operation Mounted to the periphery of a flywheel are a pair of magnetic poles south leading in clockwise rotation generated by a permanent magnet By rotating the flywheel magnetic poles clockwise past the ignition module on a laminated core group a voltage is generated in the primary winding L1 This generates a small bias current to flow through the control resistor R1 to the base of the 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 to emitter to ground The trigger sensor TS1 senses the optimum time peak current to remove the base drive from the transistor Q1 This abrupt turning off of the transistor causes an interruption in current flow which allows its associated flux collapse and several hundred volts is induced through the primary w
67. bly see Cylinder Head Assembly Removal NOTE OWhen removing the valve mechanism parts record their position to reinstall in their original position during as sembly e Remove Valve Clearance Adjusting Nuts A Rocker Arms B e Support the valve head in the combustion chamber with a suitable block e To remove the collets A push down the valve retainer B with thumbs and remove the collets e Remove the spring C and the valve D e Remove the stem seals A NOTE ORemove the stem seals only if the replacement of the stem seals is necessary OValve guide B is not replaceable do not remove it e Valve Installation OApply engine oil to the valve stems to avoid damaging the stem seals OCheck to see that the valve moves up and down smoothly in the guide OCheck the valve seating surface A between the valve B and the valve seat C e Rocker Arm Installation OSoak the valve clearance adjusting nuts and the rocker arm in the engine oil Olnstall the rocker arm www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 13 Valves Cylinder Head Cleaning and Inspection e Refer to the Cylinder Head Cleaning and Inspection in the Periodic Maintenance chapter 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
68. ce Tighten Tighten Replace Replace Adjust Change Clean Adjust See Engine power loss Replace K102052B F www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 10 6 TROUBLESHOOTING Starter Motor Troubleshooting Guide 1 Disconnect the spark plug caps from the spark plugs 2 Turn engine switch to start position and check condi tion A WARNING Engine may be cranked in this test Do not touch any rotating parts of engine and equipment during test CAUTION If starter does not stop by engine switch OFF dis connect negative cable from battery as soon as possible STARTER DOES NOT ROTATE Is there click sound from solenoid switch e Faulty battery Charge or replace e Faulty leads or connection Repair or replace e Melted fuse Replace e Faulty engine switch Repair or replace e Faulty solenoid switch Replace e Weak battery Charge or replace e Faulty leads or connection Repair or replace Solenoid to motor e Faulty solenoid switch Replace e Main terminal in solenoid e Faulty starter motor Repair or replace STARTER ROTATES BUT SLOW Is battery normal and well NO gt e Weak battery Charge or replace charged YES e Faulty leads or connection Repair or replace Solenoid to motor e Faulty solenoid switch Replace e Main terminal in solenoid e Faulty starter motor Repair or replace e Faulty
69. ceceeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeseeeseeeeeeeeeeeseeeseeteeeeseeeeeeeerees 2 17 Valve Seat Re pall EE 2 18 Cubrication SM ins 2 20 Oil Level Inspection dria a a aa ea e aaa EEN AER 2 20 Oil GANGS E 2 21 Oil Filter Replacement iiion e a a aa a a a E A a e 2 22 Ol OIE GIG ne DEE 2 22 Electrical Systemi parenii ena leek a A A A a aie a Rees 2 22 Spark Plug Cleaning and INSPeCtiON cccceeeeececeeeeeeeeeeeeeneeeeeeeeenenssenseeeeeeeeensenenseeeee 2 22 Spark Plig Gap Inspection das 2 22 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 FH451V FH500V FH531V FH541V FH580V INTERVAL P Every Every Every Every Every OPERATION Daily First Every Every 400 200 250 300 500 8 hr 25 hr 50 hr hr hr hr hr hr Check and clean air inlet screen Check and add engine oil e Check for fuel and oil leakage e Check for loose or lost n
70. cylinder and piston for damage x If there is only light damage repair the damaged piston surface with 400 emery cloth Remove the small alu minum deposits from the cylinder with 400 emery cloth or light honing x If the damage is severe the both cylinders must be bored to fit bigger size piston and install the oversized pistons www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 19 Cylinder Piston Piston Cleaning e Remove the piston and the piston rings see Piston Re moval CAUTION Never clean the piston head with the engine assem bled Carbon particles will fall between the piston and cylinder and damage the crankshaft bearings e Scrape the carbon off A the piston head e Use the scraping tools carefully Do not gouge the piston head To avoid gouging use scrapers that material will not damage the piston head e Clean the piston ring grooves A with a broken piston ring or other suitable tools CAUTION Be careful not to widen the ring grooves Damaged ring grooves will require piston replacement Piston Ring and Ring Groove Wear e Clean the piston see Piston Cleaning e Visually inspect the piston rings and ring grooves x If the piston rings are worn unevenly or damaged replace them with new ones x lf the ring grooves are worn unevenly or damaged re place both the piston and the piston rings with new ones e Check rin
71. d choke link rods during installation 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 Be sure that the fuel tube clip ends A face horizontal direction A WARNING Improper installation of the fuel inlet hose clamp can result in gasoline leakage and potential fire haz ard Be sure the clip ends of the hose clamp face in a horizontal direction In a vertical position see il lustration the clip ends A can come into contact with the inlet pipe and become loose Inlet Pipe e Adjust Carburetor Pilot Screw Idle Speed o QU O S Good Good Bad KCO5127BS2 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 24 FUEL SYSTEM Carburetor Carburetor Disassembly Assembly FH451V FH500V FH531V e Refer to the illustration for disassembly and assembly e There are several passage plugs Ball plugs in the car buretor body Do not remove them e Before disassembly mark the out side of choke valve and throttle valves for assembling them e Replace the pilot screw with a new one if necessary in accordance with the following procedure OCarefully mark the position of the pilot screw limiter on the carburetor body so that it can be installed and set to its original position later ORemove the limiter Be careful not to turn the pilot scre
72. d fins 1 Tighten nut and screws Change engine oil Clean and re gap spark plugs Check and clean oil cooler fins FH721V model Change oil filter Check and adjust valve clearance Clean and lap valve seating surface Clean combustion chambers Check air cleaner secondary element Heavy duty air cleaner model 1 Replace air cleaner secondary element Heavy duty air cleaner model 1 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 2 4 PERIODIC MAINTENANCE Torque and Locking Agent The following tables lists the tightening torque for the major fasteners and the parts requiring use of a non permanent locking agent or liquid gasket Letters used in the Remarks column mean L Apply a non permanent locking agent to the threads M Apply a molybdenum disulfide lubricant grease or oil to the threads seated surface or washer O Apply oil to the threads seated surface or washer S Tighten the fasteners following the specified sequence SS Apply silicone sealant FH451V FH500V FH531V FH541V FH580V FH451V FH500V FH531V FH541V FH580V Fastener Remarks Nm kgfm ftib Fuel System Carburetor
73. del 19 Main Nozzle 20 Valve Seat www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 25 Carburetor Carburetor Disassembly Assembly FH541V FH580V e Refer to the illustration for disassembly and assembly e There are several passage plugs Ball plugs in the car buretor body Do not remove them e Before disassembly mark the out side of choke valve and throttle valves for assembling them e Replace the pilot screw with a new one if necessary in accordance with the following procedure OCarefully mark the position of the pilot screw limiter on the carburetor body so that it can be installed and set to its original position later ORemove the limiter Be careful not to turn the pilot screw CP e at this point gt Be OTurn the pilot screw clockwise and count the number of Om turns until screw is gently seated in the pilot passage SS Record the number of turns needed to close the screw OTurn out the pilot screw to replace it with a new one Du Olnstall the new pilot screw until the screw is gently ist D seated Then open the screw the same number of turns leet as recorded prior to removal l ODO OAlign the limiter with the mark on the carburetor body to install taking care not to turn the pilot screw C e Install the choke valve and throttle valve on the shaft as E 16 the outside mark of them facing outside e Drive the float pin into the carburetor body
74. ds of the main jets High Altitude Main Jet Main Jet No FH601V FH451V FH641V FH680V and Altitude FH500V FH531V FH541V FH580V FH680V FH721V Late FH661V Models FH721V 0 1 000 m 0 3 000 ft 125 116 3 100 105 L 122 R 128 L 104 R 108 1 000 2 000 m 3 000 6 000 ft 122 5 113 8 98 100 L 119 R 125 L 101 R 105 2 000 m 6 000 ft and higher 120 98 L 116 R 122 L 98 R 102 Main Jet Replacement e Place the engine equipment on a level surface e Close the fuel shut off valve in the equipment e Drain the fuel in the carburetor completely by unscrewing the drain screw at the bottom of the float chamber e Remove the carburetor see Carburetor Removal e Unscrew the float chamber bolt A and take off the float bowl B e For Electric Starter model unscrew the solenoid valve and take off the valve and gasket www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 21 Carburetor e Using a proper standard tip screwdriver carefully replace the main jet A with a new one for expected altitude e Tighten the main jet to the specified torque see Carbure tor Disassembly Assembly Notes e Install the float chamber gasket and float bowl bolt e For Electric Stater model install the float chamber gasket and solenoid valve e For FH601V FH641V FH661V FH680V FH721V model note the follo
75. e Speed Adjustment siii ss racer 3 20 Flighltude OSO sientas doi iteraci n 3 20 Main Jet Replacement oooooocccccccnnncnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninnninness 3 20 Fuel System Cleanliness INSPectiON coooomoocionocccnnnannnccanconincnnnn anne 3 21 Carburetor Removal ea a eaa aae Eag a Eiai adia Tapada Sa EET e 3 21 Carburetor Installatlon ns nsa ea ed a a a aa a a a aa ai 3 22 Carburetor Disassembly Assembly FH451V FH500V FHD3V ooccccocccccccccccccconannnnnnnnnns 3 24 Carburetor Disassembly Assembly FH541V FHS80V cc ccceeeeeeeeeeeeceeeeeeeeeeeeeenaaeees 3 25 Carburetor Disassembly Assembly FH601V FH641V FH661V FH680V FH721V 3 26 Carburetor Disassembly Assembly FH680V and FH721V Late Models 3 27 Carburetor CIS anita sc irritada etilo E AA A aA apatia 3 29 Carburetor Inspection cccccccccccceecceeeceeeceeeceeecneceeeeceeceaeeceaecanecaaecaaecseceeeseeaeseaeenaeeaaas 3 30 Fuel Shut Off Solenoid Valve Test Electric Starter Model 3 31 Inlet Manifold WEE 3 32 Inlet Manifold REMOVAl scott ei eee ea ei Ae E OEE ERE EEEN 3 32 Inlet Manifold Installation cceccceccceccceeceeeeceeeeeeeeeeeeeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeseeeseeess 3 32 Inlet Manifold Inspechon secenek e r e a a ada E r ea atena 3 33 Fuel Pump Fuel E OT s c2 scss secscsccecadacnadesedesneedieosSsedhbacece e led 3dekataccassecagaedisacciahetsesedia
76. e inner and outer rotor with a feeler gauge Measure the clearance between the highest point of the inner rotor and the highest point of the outer rotor If the measured valve exceeds the service limit replace the rotors as a set with new ones Inner and Outer Rotor Clearance Service Limit 0 2 mm 0 008 in e Before FH500 A50136 FH531 A07510 model as shown in the figure e Measure the outside diameter A of the outer rotor with a micrometer at several points x If the rotor diameter is less than the service limit replace both the inner and outer rotor with new ones 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 If the rotor thickness is less than the service limit replace both the inner and outer rotor with new ones Outer Rotor Thickness Service Limit 9 830 mm 0 3870 in e Measure the inside diameter A of the pump housing with a inside micrometer at several points x If the inside diameter is more than the service limit re place the crankcase cover with a new one Pump Housing Inside Diameter Service Limit 40 801 mm 1 6063 in e Measure the depth B of the pump housing with a depth micrometer at several points If any of measurement is more than the service limit re place the crankcase cover with a new one Pump Housing Depth Service Limit 10 230 mm 0 4028 in www mymowerpar
77. e oil filter and oil passages in the engine Turn the filter counter clockwise to remove it Oil Filter Installation e Apply a thin layer of the engine oil to the seal A e Install new filter OTurn the filter until the seal contacts the mounting surface B of the engine Then turn the filter by hand S 3 4 turn more e Run the engine at low idle speed 2 minutes Check for leaks around the engine e Stop the engine Check the oil level see Oil Level Inspec tion 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 Engine Oil Oil Filter and Oil Cooler Oil Cooler Removal FH721V e Remove the oil filter see Oil Filter Removal e Unscrew the mounting joint A and remove the oil cooler B e Check the O ring C in the groove of the oil cooler for damage e Replace the O ring with a new one if necessary Oil Cooler Installation FH721V e Install the oil cooler with the mounting joint and tighten it Torque Oil Cooler Mounting Joint 44 N m 4 5 kgf m 33 ft lb e Install the oil filter see Oil Filter Installation Oil Cooler Cleaning e Refer to the Oil Cooler Cleaning in the Periodic Mainte nance chapter www mymowerparts com Re G FH721V5781 For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LUBRICATION SYST
78. e under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove the air cleaner see Air Cleaner Body Removal e Place a suitable container A under the drain screw B on the carburetor e Turn out the drain screw a few turns to drain the carbu retor and check if water or dirt has accumulated in the carburetor e For FH541V FH580V model remove the float bowl to drain the carburetor and check if water or dirt has accu mulated in the carburetor e Tighten the drain screw Torque FH451V FH500V FH531V Drain Screw 1 3 N m 0 13 kgf m 11 in Ib FH601V FH641V FH661V FH680V FH721V Drain Screw 2 0 N m 0 20 kgf m 18 in Ib e For FH541V FH580V model tighten the solenoid valve or float bowl mounting screw Torque Solenoid Valve 4 5 N m 0 46 kgf m 40 in Ib Float Bowl Mounting Screw 4 5 N m 0 46 kgf m 40 in Ib elf any water or dirt is found clean the carburetor see Carburetor Cleaning and fuel tank And check the fuel filter Element Cleaning and Inspection Standard Type FH451V FH500V FH531V FH541V FH580V Models NOTE Oln dusty areas clean the elements more frequently than the recommended intervals A WARNING Because of the danger of highly flammable liquids do not use gasoline or a low flash point solvent to clean the element
79. ean If ssi SE YES e Plugged air cleaner Clean emitted out o e Carbon it in exhaust hole m er NO andor muffler Sech e Carburetor is not properly Adjust adjusted e Too much oil in crankcase Adjust level Worn piston piston rings Replace Worn cylinder bore Bore or replace Is compression sufficient NO 0 See Engine hard to start Endine F ns nstabi 6 Spark plug fouled pitted or e Eng y gapped incorrectly Replace or adjust Problem in the fuel e Entry of dust or water into fuel Clean system lack of fuel pipe or fuel filter e Air or vapor lock in fuel line Clean e Plugged air vent of fuel tank cap Clean e Plugged air fuel passes in Clean carburetor e Too little opening of carburetor Correct pilot screw e Carburetor is not properly Adjust adjusted e Carburetor flange leaking at Tighten or replace gasket e Worm carburetor body and throttle shaft Replace K102050B F www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 10 4 TROUBLESHOOTING Engine Troubleshooting Guide Problem in the governor system Engine malfunction at high speed Is revolution fluctuation of relatively long period YES when a load is applied Engine malfunction at low speed Remove spark plug and check spark by cranking WEAK engine while having the plug touched against STRONG engine block WARNING Keep the plug as far away as possible from the plug hole
80. eaning and INSPeCtion eececeeeeeeee eee eeeeeeeeeeeeeeee eee eeeeeaeeeeeeeeeeeeeeenaaaes 5 13 VENA EST 5 13 Valve Clearance AdjustMent ocoooioconicnnaconnorosconccncca nn 5 13 Valve Seat ee 5 13 E e tes casapeiseccienasdi tigen tiniaagteeteas 5 13 Valve Head THICKNESS iii E E REE bei used esle teva cnes e deer 5 13 Valve Ste RUMOUL EE 5 13 Valve Stem Diameter iii AA al Rieti eine an eee naa 5 13 Valve Guide Inside Diameter 5 14 Valve Spring INSPECHON nsen e E ido did 5 14 Cylinder EIS ici A dada 5 15 Piston Removal BEE 5 15 Pistor Installationen cece edel edd ege 5 16 e Ee Te ale De 5 18 Pisto CG GAMING E 5 19 Piston Ring and Ring Groove Wear cccsscesesecceeeec eens sseeeeceneaceete cesta ccetteceeteedeneedenereenee 5 19 Piston Ring EMG Gas coset acs tha A a Re a opiate tat eae 5 20 Piston Pin Piston Pin Hole and Connecting Rod Wear 5 20 Piston DIAMOOR iia A a a 5 21 Cylinder Inside RE E 5 21 Cylinder Boring and HORNO estaa aaa 5 22 Muffler Exhaust Pipe Installation cccccecceeeceee cece cece eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeteseneeees 5 24 Muffler Exhaust Pipe Hemoval EEEE EEEE EEEE EEEE 5 24 Muffler Exhaust Pipe Installaton 5 24 INSPOCHON cccccvesvevenvasetcaecec A A A da 5 25 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 606 678 962
81. eceessdeceteeceeeeceeeesceneecenes tesbedseuseectteseeteedensecenee 4 4 A www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 2 COOLING SYSTEM Exploded View www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 COOLING SYSTEM 4 3 Exploded View FH451V FH500V FH531V T1 3 9 N m 0 40 kgf m 35 in lb T2 5 9 N m 0 60 kgf m 52 in lb T3 17 N m 1 7 kgfm 12 0 ft lb T4 56 N m 5 7 kgfm 41 ft lb T5 7 8 N m 0 80 kgf m 69 in lb FH541V FH580V T1 3 9 N m 0 40 kgf m 35 in lb T2 5 9 N m 0 60 kgf m 52 in lb T3 17 N m 1 7 kgfm 12 0 ft lb T4 56 N m 5 7 kgfm 41 ft lb T5 7 8 N m 0 80 kgf m 69 in Ib FH601V FH641V FH661V FH680V FH721V T1 3 9 N m 0 40 kgf m 35 mb T2 5 9 N m 0 60 kgf m 52 in lb T3 17 N m 1 7 kgfm 12 0 ft lb T4 56 N m 5 7 kgfm 41 ft lb T5 7 8 N m 0 80 kgf m 69 in lb Stud Before 2002 4 Product Model Stud On and after 2002 5 Product Model Cooling Fan Late Model Cooling Fan Early Model Recoil Starter Model Electric Starter Model DS P GA A 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 Electrical System chap ter Cooling Fan Installation e Refer to the Flywheel Installation in Electrical System chapter Cooling Fa
82. ecessary to loosen the nuts easily e Remove the gaskets e Unscrew the hook nut D separate the exhaust pipe and the pipe cover e Do not use unnecessary force on the exhaust pipes when removing the muffler assembly or they could become damaged or distorted Muffler Exhaust Pipe Installation e Clean the exhaust pipe flanges to the exhaust port gasket surfaces and install a new gaskets each time the muffler installation e Install the gasket e To prevent mis threading tighten the flange nuts by finger first Next tighten the hook nut e Tighten the nuts to the specified torque Torque Exhaust Pipe Flange Nuts 15 N m 1 5 kgf m 11 ft Ib e Install the muffler e After installation thoroughly warm up the engine wait un til the engine cools down and retighten the bolts and nuts www mymowerparts com KEO7010BS1 For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 25 Muffler Exhaust Pipe Installation Inspection e Inspect the exhaust pipe or muffler for dents cracks rust and holes x lf the exhaust pipe or muffler is damaged replace the exhaust pipe or the muffler with a new one for the best performance and minimum noise e Check the muffler for distortion and or loose internal com ponents Loose internal components may result in the ex haust flow restriction and the engine output decrease e Check for breaks in the seams and check weld at the junction
83. eign particles Don t use just any oil or grease Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended This manual makes reference to molybdenum disulfide grease MoS2 in the assembly of certain engine parts Always check manufacturer recommendations before using such special lubricants 17 Electrical Wires All the electrical wires are either single color or two color and with only a few exceptions must be connected to wires of the same color On any of the two color wires there is a greater amount of one color and a lesser amount of a second color so a two color wire is identified by first the primary color and then the secondary color For example a yellow wire with thin red stripes is referred to as a yellow red wire it would be a red yellow wire if the colors were reversed to make red the main color Wire cross section Color Indicated on the Wire Color Indicated on the Wiring Diagram Red Wire Strands Yellow Red Yellow Red 6B020601w1 18 Replacement Parts When there is a replacement instruction replace these parts with new ones every time they are removed There replacement parts will be damaged or lose their original function once removed 19 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as
84. ement and primary element into place in the air cleaner body 4 e Install the cap A direction as shown Mark B Upside C e Fasten the two retaining clamps D KC06011BS1 For FH541V FH580V e Slide the element into place in the air cleaner body e Install the cap A direction as shown Mark B Upside C 15 D e Fasten the two retaining clamps E KC06027BS1 Element Cleaning and Inspection e Refer to the Element Cleaning and Inspection in the Pe riodic Maintenance chapter www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 Air Cleaner Heavy Duty Type FUEL SYSTEM 3 39 Air Cleaner Body Removal e Remove the air cleaner elements see Element Re moval e Loosen the clamps A and remove the inlet hose B e Remove the bolt C e Take out the air cleaner body D from the arrow side E in the figure Air Cleaner Body Bracket Bolts F Air Cleaner Body Bracket G For FH541V FH580V Clamps A Inlet Hose B Bolt C Air Cleaner Body D Arrow Side E Air Cleaner Body Bracket Bolts F Air Cleaner Body Bracket G iy oak A F F O d o i e O del 20 Y A a es YO p KC06028B92 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 40 FUEL SYSTEM Air Cleaner Heavy Duty Type Air Cleaner Body Installation e Inst
85. g grooves for wear by inserting a new ring in the proper groove at several points around the piston e Measure the clearance between the top and second rings and their grooves using a thickness gauge A as shown in the figure x If the piston ring groove clearance is greater than the ser vice limit replace the piston with a new one Piston Ring Groove Clearance Service Limit FH601V FH641V FH451V FH500V FH541V FH661V FH680V FH531V FH580V FH721V 0 15 mm 0 006 in 0 18 mm 0 007 in Second 0 12 mm 0 005 in 0 16 mm 0 006 in NOTE OThe oil ring is a three piece assembled ring It is diffi cult to measure the ring groove clearance and the thick ness Visually inspect the oil ring the ring groove clear ance and the oil ring thickness www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 20 ENGINE TOP END Cylinder Piston e Measure the piston ring thickness A OUse a micrometer to measure the ring thickness at several points around the rings x If any of the measurement are less than the service limit replace the entire set of rings with new ones Piston Ring Thickness Service Limit Top Second 1 40 mm 0 055 in NOTE OWhen using new rings in a used piston check if the groove wear is even The rings should fit perfectly par allel to the groove sides If not replace the piston with a new one Piston Ring End Gap e Remove
86. haft bearing inside diameter Relief valve spring free length Service Limit 0 2 mm 0 008 in 40 470 mm 1 5933 in 9 830 mm 0 3870 in 40 801 mm 1 6063 in 10 230 mm 0 4028 in 10 923 mm 0 4300 in 11 072 mm 0 4359 in 19 50 mm 0 77 in Special Tool Oil Filter Wrench 57001 1249 Sealant Kawasaki Bond Silicone Sealant 56019 120 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LUBRICATION SYSTEM 6 7 Engine Oil Oil Filter and Oil Cooler CAUTION Engine operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure and accident Before starting the engine for the first time add oil The engine is shipped dry Preoil the engine to force all air from the internal oil passages and the oil filter e Fill fresh engine oil to the specified level see Oil Level Inspection e Run the engine at slow speed for 2 minutes e Stop the engine and check the oil level 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 Removal e Using a strap wrench or oil filter wrench A remove the oil filter B Special Tool Oil Filter Wrench 57001 1249 OWhen unscrewing the oil filter place a suitable container beneath the oil drip tray to receive oil from th
87. he measured height differ ences If connection rod twist exceeds the service limit replace the connecting rod with a new one Connecting Rod Twist Service Limit 0 15 100 mm 0 006 3 94 in Connecting Rod Big End Crankpin Width Wear e Measure the connecting rod big end width A with a mi crometer or a dial caliper x If the measurement is less than the service limit replace the connecting rod with a new one Connecting Rod Big End Width Model Service Limit FH451V 500V 531V 18 80 mm 0 74 in FH541V 580V 18 80 mm 0 74 in FH601V 641V 661V 680V 721V 19 90 mm 0 783 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 7 17 Crankshaft Connecting Rod e Measure the crankpin width A with a dial caliper x If the crankpin width is greater than the service limit re place the crankshaft with a new one Crankpin Width model Service Limit FH451V 500V 531V 39 50 mm 1 56 in FH541V 580V 39 50 mm 1 56 in FH601V 641V 661V 680V 721V 43 1 mm 1 697 in Connecting Rod Big End Bearing Crankpin Wear e Apply a thin layer of oil on the threads of the cap bolts e Install the cap bolts and tighten the bolts to the specified torque see Piston Installation in Engine Top End chap ter e Measure the big end inside diameter A at several points with a telescoping gauge or inside micrometer x lf the inside di
88. he service limit turn down the commutator or replace the armature with a new one Commutator Runout Service Limit 0 4 mm 0 016 in e Measure the armature winding resistance OSet the hand tester to the R x 1 Q range and measure the resistance between each segment A and all the others x If the resistance it too high or even infinite the armature winding has an open circuit Replace the starter motor with a new one Armature Winding Resistance Close to 0 Q e Set the hand tester to the R x 1 kQ range and measure Ge ere the resistance between the commutator and the armature shaft B x lf the resistance is less than infinite the armature is shorted Replace the starter motor with a new one Commutator to Shaft Resistance dell www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 8 STARTER SYSTEM Starter System e Test the armature winding for shorts OPlace the armature on a growler A OHold a thin metal strip e g hack saw blade on top of the armature OTurn on the growler and rotate the armature one complete turn x lf the metal strip vibrates the windings are internally shorted to each other replace the starter motor with a new one Yoke Assembly Inspection e Set the hand tester to the R x 1 kQ range and measure the resistance between the positive brush es A and brush plate B x If the resistance is less than infinite the positive brush is s
89. horted to ground Replace the brush plate assembly with a new one Positive Brush to Ground Resistance gt e Set the hand tester to the R x 1 Q range and measure the resistance between the negative brush es A and brush plate B If the meter does not read close to 0 Q the brush plate is faulty Replace the brush plate assembly with a new one Negative Brush to Ground Resistance Close to 0 Q Pinion Clutch Inspection e Turn the pinion gear by hand The pinion gear should turn clockwise freely x If the pinion clutch does not operate as it should or if it makes noise replace the pinion clutch with a new one Recoil Starter Removal e Remove Recoil Starter Mounting Nuts A Recoil Starter B Recoil Starter Installation e Install the recoil starter and tighten the mounting nuts Torque Recoil Starter Mounting Nuts 5 9 N m 0 60 kgf m 52 in lb www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 STARTER SYSTEM 8 9 Starter System Recoil Starter Disassembly e Remove the recoil starter see Recoil Starter Removal e Pull the handle A out 30 cm 1 ft and clamp the rope B with the clip C so it can not wind back onto the reel D e Pry the knot E out of the handle and untie it e Remove the handle from the rope A WARNING Wear gloves to avoid injury for the remaining steps e While carefully holding the reel A and case B remo
90. iameter Crankcase Cover 1 384 in 1 581 in Crankshaft Journal Bearing 35 15 mm 40 15 mm Inside Diameter Crankcase 1 384 in 1 581 in For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 7 5 Crankcase Crankcase Cover Removal e Set the engine on a clean surface while parts are being removed e Drain the oil see Lubrication System chapter e Remove Exhaust Pipe and Muffler see Engine Top End chapter Control Panel see Fuel System chapter Governor Arm see Fuel System chapter e Unscrew the mounting bolts A and remove the crankcase cover B from the crankcase OThere are two knock pins on the crankcase mating surface Using a wooden or plastic mallet gently tap crankcase to loosen the crankcase cover Crankcase Cover Installation e Remove the old gasket from the mating surfaces of the crankcase and cover e Using compressed air blow out the oil passage in the crankcase cover e With a high flash point solvent clean off the mating sur faces of the crankcase and the cover and wipe them dry A WARNING Clean the crankcase and cover in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean parts A fire or explosion could result e Be sure to replace any oil seal with a new one Olnstall the oil seal
91. icles on 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 If the screen is damaged replace it with a new one 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 WEE 7 2 Specifications iS A A A a AA 7 4 EE EE lt A Een ee E EEN 7 5 Crankcase Cover Remova a a dra a Na 7 5 Crankcase Cover Installaton 7 5 Inspection Ae iS LA UDR de aie ee Meo ue Eege 7 6 A lr e EE 7 7 Br E 7 8 Breather Element Removal FH451V 500V 531V 541V DOUM 7 11 Breather Element Installation FH451V 500V 531V 541V BB 7 11 Breather Valve Inspection FH601V 641V 661V 680V 721V cooooconccnnnnnncnccenencninnonons 7 11 Camshaft Tapetes casa 7 12 Camshaft Tappet Removal 7 12 Camshaft Tappet Installaton 7 12 Camshaft Ru UE 7 13 Camshat ee eegene dee dE Ee ESA 7 13 Camshaft INSPECUON sarsniinr na EREECHEN 7 13 Camshaft Bearing Journal Wear c ccccccccseseeceeeeceeeeenessecceneeneneeeennnsneeseneeeeeeseseesnnenes 7 13 Crankshaft Connecting Rod 7 15
92. iew 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 De VICI EEEE ATEA iia det Model Identification A a is General Gpechficatons a A E A E E EA www mymowerparts 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 Battery Ground Remove the ground lead from the battery before performing any disassembly operations on the equipment This prevents a the possibility of accidentally turning the engine over whi
93. il seal O 1 0 mm 0 04 in B flush or below the crankcase cover surface C KCO4013BS1 Governor Shaft Installation e Apply engine oil to the governor shaft e Insert the governor shaft into the crankcase e Install the governor shaft plate A to the shaft B as shown in the figure Torque Governor Shaft Plate Screws 2 0 N m 0 20 kgf m 17 in Ib e Check that the governor shaft moves freely in its operating range NOTE Olf the oil seal is removed install the governor shaft first then install the oil seal www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 18 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 of the main nozzle end into the carburetor bore where it is atomized by the high speed air flow and carried into the engine Main Fuel Flow Main System Fuel and Air Supply Air Cleaner Carburetor Bore e KCO5125BW3 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 19 Carburetor The pilot syste
94. il spring e Set the recoil spring into the spring cassette e Wind the rope clockwise A on the reel and hold the rope end B with tape e Install the spring cassette C on the reel so that the tongues D on the cassette fit in the openings of the reel e Lightly grease the shaft A e Put the reel into the case with the round peg B aligned with the spring inner tongue C e Turn the reel clockwise until you feel the spring inner tongue catches the round peg e Install Return Springs A and Pawls B Washer C and Center Spring D e Lightly grease the center spring www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 STARTER SYSTEM 8 11 Starter System e Install Retainer A Washer B Screw C Torque Recoil Starter Retainer Screw 7 8 N m 0 80 kgf m 69 in Ib e Turn the reel two turns counterclockwise to preload the recoil spring e While holding the reel to keep it from unwinding feed the en end of the rope through the hole in the case 4 e Clip the rope as shown to hold it e Install the handle A and secure it with a knot B e Remove the clip C to release the rope 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 9 1 Electrical System Table of Contents E leie e WEE 9 2 SPEC
95. in 0 5 mm 0 02 in 74 99 mm 2 952 in 0 18 mm 0 007 in 0 16 mm 0 006 in 1 40 mm 0 055 in 0 65 mm 0 026 in 0 78 mm 0 031 in 1 05 mm 0 041 in 15 96 mm 0 628 in 16 08 mm 0 633 in 16 05 mm 0 632 in 75 28 mm 2 964 in 75 78 mm 2 983 in Cylinder Inside Diameter Out Round 0 056 mm 0 0022 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 8 ENGINE TOP END Specifications Special Tools Piston Ring Pliers 57001 115 Compression Gauge 20 kgf cm 57001 221 Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 67 79 57001 1097 Compression Gauge Adapter M14 x 1 25 57001 1159 Valve Seat Cutter Holder Bar 57001 1128 Valve Seat Cutter Holder 6 57001 1360 Valve Seat Cutter 45 635 57001 1116 Valve Seat Cutter 32 633 57001 1199 Valve Seat Cutter 45 630 57001 1187 Valve Seat Cutter 32 630 57001 1120 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 9 Cylinder Head Compression Measurement e Before measuring compression check 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 sealing the compression as it does during normal running OStop the engine e Disconnect the spark plug caps of each cylinder and re move the spark plugs e
96. inding 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 the constant timing over speed and temperature and prevents counterclockwise operation The diode D1 in the ignition shut off circuit blocks the inadvertent application of the battery voltage protecting the internal components of the ignition With the stop switch SW in the closed position the primary voltage is routed to ground preventing the ignition operation www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 9 17 Ignition System Ignition Coil Removal e Remove Fan Housing see Flywheel Stator Coil Removal Spark Plug Cap A Stop Switch Lead Connector B Bolts C Ignition Coil D Ignition Coil Installation e Install the ignition coil on the crankcase so that the stop switch lead connector B face the screen and tighten the bolt 1 first then tighten the bolts 2 While tightening bolts adjust the air gap A between the three legs of igni tion coil and the two pole plates of magnet to the specified gap value as shown in the figure Ignition Coil Air Gap Standard 0 2 0 4 mm 0 008 0 016 in 1 kHo7oosss1 e Torque Ignition Coil Bolts Stud Bolt 7 8 N m 0 80 kgf m 69 in Ib Ignition Coi
97. ion Engine Oil 10 W 30 Engine Oil Temperature 50 60 C Oil Pressure Switch PT 1 8 Taper Pipe Threads www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 10 LUBRICATION SYSTEM Pressurized Lubrication System Oil Pressure Switch Inspection When the oil pressure falls below 98 kPa 14 2 psi the oil pressure switch activates the oil warning lamp to alert the operator or lubricating problem e To check the oil warning system insert the switch key into the engine switch at the OFF position then turn the switch key to the RUN position The warning light must be illuminated e When the engine is running be sure the warning light is OFF x If the warning light comes on stop the engine immediately and check the oil level e When starting the engine note the warning light on dash carefully x lf the warning light is on when the engine starts in spite of adequate oil level check the lead from the pressure switch to the warning light for short circuit and or check the pressure switch and replace damaged part with a new one x lf the light is not on at the moment of the engine switch operation check all leads of the warning light circuit or bulb and replace damaged parts with new ones www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LUBRICATION SYSTEM 6 11 Oil Pump Relief Valve Oil Pump Relief Valve Removal e Remove the crankca
98. ith a new one if necessary e Inspect the plate B for damage or rough contact surface replace it with a new one if necessary e Inspect the valve seating surface The surface should be no nicks or burrs e Be sure that the drain hole on the breather chamber is not accumulated with slugs before installing the breather valve e Align the center of the valve seat with the center of the breather valve and the plate then tighten the mounting screw NOTE OThe mounting screw is a self tapping one Be aware that misthreading or overtightening screw will strip the female threads and break the hole www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 12 CAMSHAFT CRANKSHAFT Camshaft Tappet Camshaft Tappet Removal e Set the engine on a clean surface while parts are re moved e Drain the oil see Lubrication System chapter e Remove Muffler see Engine Top End chapter Throttle Control Panel see Fuel System chapter Carburetor see Fuel System chapter Inlet Manifold see Fuel System chapter Crankcase Cover see Crankcase Cover Removal Rocker Covers A e Position the piston at the TDC of the compression stroke e Push down A the spring side of the rocker arm B and move it to clear the push rod C e Remove the push rods and mark them so they can be installed in their original positions during assembly e Turn the crankcase upside down so that the tappets will fall away from the
99. l Bolts Flanged Bolt 5 9 N m 0 60 kgf m 52 in Ib NOTE OUse the above procedure to insure proper coil air gap KHO7O04BS1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 9 18 ELECTRICAL SYSTEM Ignition System Ignition Coil Inspection e Remove the ignition coils see Ignition Coil Removal e Measure the winding resistance as follows OSet the hand tester to the R x 1 kQ range Special Tool Hand Tester 57001 1394 OMeasure the ignition coil winding resistance as shown in the table Ignition Coil Winding Resistance SE o veka fow DN CAUTION Use only Tester 57001 1394 with new battery at room temperature for this test A tester other than the Kawasaki Hand Tester should show different readings If a megger or a meter with a large capacity battery is used the ignition coil will be damaged x If the tester does not read as specified replace the coil with a new one Spark Plug Cleaning and Inspection e Refer to the Spark Plug Cleaning and Inspection in the Periodic Maintenance chapter Spark Plug Gap Inspection e Refer to the Spark Plug Gap Inspection in the Periodic Maintenance chapter www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING 10 1 Troubleshooting Table of Contents Engine Troubleshooting Guide E 10 2 Starter Motor Troubleshooting Guide siii da 10 6 www mymowe
100. le partially disassembled b sparks at electrical connections which will occur when they are disconnected c damage to electrical parts 3 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 4 Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench 5 Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removal of screws held by a locking agent in order to avoid damaging the heads 6 Edges Watch for sharp edges especially during major engine disassembly and assembly Protect your hands with gloves or a piece of thick cloth when lifting the engine
101. m 0 17 kgf m 15 in Ib T5 2 0 N m 0 20 kgf m 17 in Ib T6 3 4 N m 0 35 kgf m 30 in Ib T7 5 9 N m 0 60 kgf m 52 in Ib T8 6 9 N m 0 70 kgf m 61 mini T9 8 8 N m 0 90 kgf m 78 in lb www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 4 FUEL SYSTEM Exploded View FH541V FH580V 6 Quad A JAS SY XX Ca 4 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 5 Exploded View FH541V FH580V Pilot Screw Main Jet Solenoid Valve 0 7 N m 0 07 kgf m 6 in Ib 2 3 Nm 4 5 N m 0 46 kgf m 40 in Ib 3 4 N m 0 35 kgf m 30 mb T5 0 23 kgf m 20 in Ib 5 9 N m 0 60 kgf m 52 mb L Apply non permanent locking agent www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 6 FUEL SYSTEM Exploded View Heavy Duty Air Cleaner Type Kc02049BW5 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 7 Exploded View Heavy Duty Air Cleaner Type Pilot Screw Main Jet Solenoid Valve 0 7 N m 0 07 kgf m 6 in Ib gt 2 3 Nm 4 5 N m 0 46 kgf m 40 in Ib 5 9 N m 0 60 kgf m 52 in Ib T5 0 23 kgf m 20 in Ib 9 8 N m 1 0 kgf m 87 in lb L Apply non permanent locking agent www mymowerparts com For Kawasaki Discount Parts Call 606 6
102. m 0 94 in o 26 mm 1 02 in Venturi Diameter 16 mm 0 63 in 18 mm 16 mm 18 mm 21 mm 0 83 in 0 71 in 0 63 in 0 71 in 18 mm 0 71 in Main Jet MJ 125 116 3 100 105 L 122 R 128 L 104 R 108 Pilot jet PJ 48 8 43 8 48 50 L 46 R 44 52 Main air jet MAJ 01 7 01 4 150 110 1 7 p1 6 Pilot air jet PAJ 1 2 0 8 170 140 1 1 p1 4 Pilot Air Screw Turns out 2 1 4 1 3 8 2 1 2 1 7 8 L 2 1 4 R 1 1 4 PS Idle Mixture Screw L 3 R 2 1 4 Turns Out Heavy duty type Paper element Primary element Secondary element 1 Idle speeds may vary depending on each equipment Refer to the equipment specification For FH680V and FH721V Late Models www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 15 Governor Link Mechanism Control Panel Assembly Removal e Remove Air Cleaner see Air Cleaner Body Removal Air Cleaner Mount Bracket Bolts A Air Cleaner Mount Bracket B Ground Lead Electric Starter Model Control Panel Mounting Bolts C e Remove the control panel assembly A while unhooking the governor spring B end loop at the panel bracket e Clear the choke link rod lower end C from the choke lever Control Panel Assembly Installation e Before installing the control panel assembly check to see that the choke lever A and engine speed control lever B move smoothly in all di
103. m Lobe Height Service Limit FH451V 500V 531V IN 29 131 mm 1 1469 in EX 29 131 mm 1 1469 in FH541V 580V IN 29 131 mm 1 1469 in EX 29 131 mm 1 1469 in FH601V 641V 661V 680V IN 29 621 mm 1 166 in EX 29 621 mm 1 166 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 14 CAMSHAFT CRANKSHAFT Camshaft Tappet e Measure both camshaft journals at several points around the journal circumference x lf the journal diameter is less than the service limit re place the camshaft with a new one PTO Side Camshaft Journal Diameter Service Limit 15 985 mm 0 6293 in Flywheel Side Camshaft Journal Diameter Service Limit 15 985 mm 0 6293 in e Measure the inside diameter A of the camshaft bearing on the crankcase at several points This bearing is not replaceable x If the inside diameter is greater than the service limit re place the crankcase with a new one Camshaft Bearing Inside Diameter Crankcase Service Limit 16 136 mm 0 6352 in e Measure the inside diameter A of the camshaft bearing on the crankcase cover at several points This bearing is not replaceable x lf the inside diameter is greater than the service limit re place the crankcase cover with a new one Camshaft Bearing Inside Diameter Crankcase Cover Service Limit 16 136 mm 0 6352 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 5
104. m includes the pilot jet F pilot screw G Idle mixture screw pilot air jet H pilot outlet I and the bypass holes J The pilot system meters the fuel air 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 to atomize it Instead the fuel is drawn through the pilot system since the nearly closed throttle valve K causes high speed air flow through the pilot outlet and bypass holes even at low engine speed Fuel flow in the pilot system is metered by the pilot jet Air for better atomization is admitted via the pilot air jet in the mouth of the carburetor The fuel air mixture passes into the bore of the carburetor side stream of the throttle valve through the bypass holes and pilot outlet While the throttle valve is almost closed it covers the small bypass holes opening into the bore from the pilot system As the throttle valve begins to open it uncovers the bypass holes 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 pilot screw controls the amount of fuel air mixture allowed through the pilot outlet but does not meter the bypass holes A moderate amount of air comes in around the throttle valve at an idle so adjusting the pilot screw changes the fuel air ratio Tu
105. mary Winding Resistance in the text Secondary Winding Resistance 8 to 11 kO EE Spark Plug CHAMPION RCJ8Y NGK BPR4ES Plug Gap 0 75 mm 0 030 in 0 75 mm 0 030 in Special Tool Hand Tester 57001 1394 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 9 5 Wiring Diagram FH451V FH500V FH531V FH541V FH580V Electric Starter Model Note Portion surrounded byzy shows KHI procurement parts Spark Plugs ar A Y N SVA Flywheel STE Coil Option Oil Pressure Switch Oil Lamp SSA START Y Starter ng S na A www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 9 6 ELECTRICAL SYSTEM Wiring Diagram FH451V FH500V FH531V Recoil Starter with Charging Coil Model Note Portion surrounded byzy shows KHI procurement parts Spark Plugs QQ RW G VAEN Coil rT To Electric Clutch 12V DC Engine Stop Switch www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 9 7 Wiring Diagram FH451V FH500V FH531V Recoil Starter Model Note Portion surrounded by zzz shows KHI procurement parts Flywheel O Engine Stop Switch www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 9 8 ELECTRICAL SYSTEM Wiring Diagram FH601V FH641V FH661V FH680V FH721V Electric Star
106. measure the inside diameter A of the valve guide B at three positions down the guide length x If the measured valve diameter is greater than the service limit replace the cylinder head with a new one Valve Guide Inside Diameter Service Limit Inlet Exhaust 6 08 mm 0 239 in Valve Spring Inspection e Inspect the valve spring for pitting cracks rusting and burns Replace the spring with a new one if necessary e Measure the free length A of the spring x If the measured free length is less than the service limit replace the spring with a new one Valve Spring Free Length Service Limit 31 0 mm 1 22 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 15 Cylinder Piston Piston Removal e Split the crankcase see Camshaft Crankshaft chapter e Remove the camshaft see Camshaft Crankshaft chap ter e Turn the crankshaft to expose the connecting rod cap bolts A e Remove the bolts and take off the connecting rod caps B NOTE ORecord the positions of the connecting rod caps for re installing the caps e Push the connecting rod end into the cylinder and pull the piston and connecting rod out of the cylinder CAUTION Note a location of the arrow match mark A on the piston head in relation to K Mark B on the connect ing rod No 1 cylinder K Mark on the connecting rod is face to face with No 2 cylinder K Mark
107. n revolution s per minute top dead center total indicator reading volt s watt s ohm s www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 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 opti mum 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 maintena
108. n Inspection e Visually inspect the blades A in the cooling fan B x If they have any crack warp or damage replace the cool ing fan with a new one If any mud or dust have stuck to the cooling fan clean it e Wash the cooling fan in detergent and water CAUTION Do not clean the cooling fan in oil solvent It may be damage by oil solvent Screen Clearance Adjustment e Check the clearance between the screen A and the fan housing B If the clearance is less than 1 mm 0 04 in add proper number of the spacer C between the screen and the bracket comp D to adjust the clearance G 1 3 mm 0 04 0 12 in Screws F Clearance 1 3 mm 0 04 0 12 in G 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 WE 5 2 Specifications Tdci 5 6 Cylinder Head EE 5 9 Compression Measurement 5 9 Cylinder Head Assembly Removal cccccccceececccceeeeeeeseceeeneceeeeenennnsseneeeeeseeeesenneneeseee 5 10 Cylinder Head Assembly Installation ceccceccecceeeeeeseeecceeeeneteeeeseneeeeeneeeeeeeeeneeeeneee 5 10 Push Rod Removal aa a a aE aE a a Push R dinstallatioMe 0 A a see an PUSH ROA Mie ee de ln EG Valve Mechanism Removal Installati0N cccccecceeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeneeess 5 12 MAIS Eed Ee Daa ocak ste tc 5 13 Cylinder Head Cl
109. n from the governor arm is approximately 7 mm 0 3 in H as shown in the figure e Install the control panel assembly and connect the gov ernor arm with the governor spring Governor Assembly Removal e Remove the crankcase cover see Camshaft Crankshaft chapter e Remove the push rod see Engine Top End chapter e Remove the camshaft A e Remove Washer A Snap Ring B Sleeve C Governor Plate D Snap Ring B Steel Balls E Ball Guide F Ball Plate G www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 17 Governor Link Mechanism Governor Assembly Installation e Fit the snap ring A into the groove securely e Turn the governor plate by hand and check that the steel balls and governor plate move freely Governor Assembly Inspection OVisually check all governor parts for wear or damage x If any parts are worm or damaged replace them with new ones Governor Shaft Removal e Split the crankcase see Camshaft Crankcase chapter e Unscrew the governor shaft plate screws A and pull out the governor shaft B NOTE ORemove the governor shaft only if the replacement of the governor shaft is necessary e Replace the oil seal with a new one only if the lip shows signs of leakage or it has been damaged e Assemble the oil seal A Be sure that the seal lip must face the inside of the engine e Press in the o
110. nce repair or replacement of any device or element of design incorporated into any new engine for the purpose of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the engine after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Do not tamper with the original emission related part e Carburetor and internal parts e Spark plugs e Magneto or electronic ignition system e Fuel filter element e Air cleaner elements e Crankcase e Cylinder heads e Breather 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 mistake
111. necessary e Inspect the springs for weakened conditions and distor tion x Replace the springs with new ones if necessary If the brush springs can press the brushes firmly into place they may be considered serviceable If they can not replace them with new ones Armature Inspection e Inspect the surface of the commutator A x If it is scratched or dirty polish it with a piece of very fine emery cloth B and clean out the grooves GP110610S1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 STARTER SYSTEM 8 7 Starter System e Measure the depth of the grooves between the commu tator segments x If the grooves are shallower than the specified limit re O place the armature with a new one P x If the grooves are only dirty clean them carefully Commutator Groove Depth Limit 0 9 mm 0 035 in Bad A Segment B Good C 0 9 mm 0 035 in limit D Mica E e Measure the diameter A of the commutator B at several points x If the diameter is less than the service limit replace the armature with a new one Commutator Outside Diameter Service Limit 31 1 mm 1 225 in GP110607S1 e Support the armature in an alignment jig at each end of the shaft as shown in the figure Position a dial indicator perpendicular to the commutator e Rotate the armature slowly and read the commutator runout x If runout is greater than t
112. ner Pre cleaner Second stage cleaner 1 550 r min rpm 3 600 r min rpm Dual stage filtration system Foam element Paper element FH601V FH641V FH661V FH680V FH721V FH451V FHSOOV FH531V FH541V FH580V Heavy duty type Paper element Primary element Secondary element Engine Top End Valve Clearance Inlet Exhaust Valve Seating Surface Angle Inlet Exhaust Valve Seating Surface Width Inlet Exhaust Lubrication System Engine Oil Type Viscosity Capacity Level 0 10 0 15 mm 0 004 0 006 in 45 0 6 0 9 mm 0 024 0 035 in SF SG SH SJ or SL class SAE 40 SAE 30 SAE 10W 30 SAE 10W 40 or SAE 5W 20 1 5 L 1 6 US qt When the oil filter is not removed 1 7 L 1 8 US qt When the oil filter is removed except FH721 1 8 L 1 9 US qt When the oil filter is removed FH721 Operating range grid area on dipstick ee Electrical System Spark Plug Spark Plug Gap CHAMPION RCJ8Y NGK BPR4ES 0 75 mm 0 030 in O e Service Um Engine Top End Cylinder Head Warp 0 05 mm 0 002 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 10 PERIODIC MAINTENANCE Special Tools Valve Seat Cutter 45 635 57001 1116 Valve Seat Cutter 32 430 57001 1120 ST5711168T ST5711208T
113. ng Screw Carburetor 3 9 0 40 35 in lb Governor Arm Clamp Nut 7 8 0 80 69 in lb Governor Shaft Plate Screws 2 0 0 20 18 in lb Inlet Pipe Mounting Bolts and Nuts 5 9 0 60 52 in lb Inlet Manifold Mounting Bolts 5 9 0 60 52 in lb Air Cleaner Body Mounting Screws Air Cleaner Body Bracket Bolts Heavy Duty 5 9 0 60 52 in lb Air Cleaner Type Air Cleaner Body Bracket Nuts Heavy Duty 9 8 1 0 87 in lb Air Cleaner Type Control Panel Mounting Bolts 5 9 0 60 52 mb Cooling System Engine Shroud Bolt M8 11 Engine Shroud Bolts M6 52 in lb Plug Bolt Engine Shroud mm Plug Screw Engine Shroud S 30 in lb Engine Top End Cylinder Head Bolts 25 2 6 19 S Valve Clearance Lock Screws 6 9 0 70 61 in lb Connecting Rod Big End Cap Bolts 21 2 1 15 O For M7 x P1 0 screw thread spec www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 8 PERIODIC MAINTENANCE Torque and Locking Agent FH601V FH641V FH661V FH680V FH721V Fasteners Torque Remarks N m kgf m ft Ib Connecting Rod Big End Cap Bolts 9 8 1 0 87 in lb O For M6 x P1 0 screw thread spec Rocker Arm Bolts 28 2 8 20 Rocker Cover Mounting Bolts 5 9 0 60 52 in lb Exhaust Pipe Flange Nuts 15 1 5 11 Spark Plugs 22 2 2 16 Lubrication System Engine Drain Plugs Plastic 6 9 0 70 61 in lb Engine Drain Plug Metal 20 2 0 14 5 Engine Drain Plug Joint Plastic 17 1 7 12 Engine Drain Plug Joint Metal 39 4 0 29 Oil Pressure
114. nstallation e Clean the starter motor and engine mounting flanges to ensure good electrical contact and tighten the mounting bolts Torque Starter Motor Mounting Bolts 15 N m 1 5 kgf m 11 0 ft Ib Starter Motor Disassembly e Remove Through Bolts and Nuts A Brush Plate B York C Cap D e While pushing the collar A remove the snap ring B e Remove Spring A Pinion Assembly B Washer C Bracket D Armature E www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 6 STARTER SYSTEM Starter System Starter Motor Assembly e Assemble the starter motor in the reverse of disassembly e Apply a small amount of grease A to the armature shaft e Do not reuse the snap ring B Replace it with a new one e Check the cap and replace it with a new one if damaged e Fit the projection A on the bracket into the notch B in the yoke e Press the springs and holding the brush leads with suit able clips e Put the washer C among the brushes e Fit the projection D on the brush plate into the notch E in the yoke Starter Motor Brush Inspection e Measure the overall length of each brush A x If the brushes are shorter than the service limit replace them with new ones Brush Length Service Limit 6 4 mm 0 25 in Brush Spring Inspection e Inspect the brush springs for pitting cracks rusting and burrs x Replace the spring with a new one if
115. of the exhaust pipes and the muffler e Tap the muffler with a plastic hammer to decarbonize 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 LUBRICATION SYSTEM 6 1 Lubrication System Table of Contents EXPO TEE 6 2 Engine Oil een ed Ra AE A eats 6 4 E gine Qil e EE 6 5 Specifications amic oasis 6 6 Engine Oil Oil Filter and Oil Gooler 6 7 Oil Level Inspechon 6 7 RONG VAIN ido dels tea ok bello oo 6 7 Oil Filter Removal e cocinas died Oil Filter Instala a ek ere Oil Filter Replacement anasnaoenennnnneeeneeeeeseeereeerttetterttertttetttrtteerttetteertrrttertterrtrerrrertereeet Oil Cooler Removal ZER KN tie ee egene e a Oil Cooler Installation FH721V EE 6 8 Oil Cooler CIS ARMING tii A Gee eet ee ee Mea a EIA AA hee 6 8 Pressurized Lubrication System a da redil lidia 6 9 Oil Pressure Measurement coccccnnncnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninnnnnnennnness 6 9 Oil Pressure Switch Inspection sy aiae a a ee aS 6 10 OI Sdt ue WEE 6 11 Oil Pump Relief Valve Removal inrsin nen a a a E A E EEEE 6 11 Oil Pump Relief Valve Installaton 6 11 Oil Pump Relief Valve Inspechon 6 12 O OA 6 15 Oil Screen Remo TE 6 15 Oil Screen Installat ON A a a a e aa E a E a e ra ae e a daade aA EA a daaa 6 15 Cleaning and INS pection cert 6 16 www mymowerparts com For Kawasaki Discount
116. one sealant A FH451V FH500V FH531V FH541V FH580V Model B FH601V FH641V FH661V FH680V FH721V Model C Applicable Model only 1 Screw 2 Plate 3 Breather Valve www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 4 CAMSHAFT CRANKSHAFT Specifications Sealant Kawasaki Bond Silicone Sealant 56019 120 www mymowerparts com Service Limit Item FH601V 641V 661V FH451V 500V 531V FH541V 580V 680V 721V Camshaft Tappet Cam Lobe Height Inlet 29 131 mm 29 621 mm 1 1469 in 1 166 in Exha st 29 131 mm 29 621 mm 1 1469 in 1 166 in Camshaft Journal Diameter 15 985 mm E EIQ pide 0 6293 in Flywheel Side a Camshaft Bearing Inside Diameter Crankcase Uli GN Es 0 6352 in Crankcase Cover e GC ik Crankshaft Connecting Rod Connecting Rod Bend 0 15 100 mm 0 006 3 94 in Connecting Rod Twist 0 15 100 mm 0 006 3 94 in Connecting Rod Big End Width 18 80 mm 19 90 mm 0 74 in 0 783 in Crankpin Width 39 50 mm 43 1 mm 1 56 in 1 697 in Connecting Rod Big End Inside 35 055 mm 38 055 mm Diameter 1 3801 in 1 498 in Crankpin Outside Diameter 34 94 mm 37 94 mm Crankshaft Runout 0 05 mm 1 494 in 0 002 in TIR Crankshaft Journal Diameter 34 90 mm 39 896 mm OSOS 1 374 in 1 571 in ree Side ae LD Crankcase PTO Shaft Bearing Inside 35 15 mm 40 15 mm D
117. ositions on each cylinder see Push Rod Installation e Install the knock pins e Set each piston at the T D C A of the compression stroke e Put new gaskets and the cylinder head assemblies on each cylinder then let the cylinder heads with push rods aligned under the rocker arms NOTE OAs the head gaskets are coated with sealing agents be careful not to damage the surfaces KEO4013BS1 KEO4013BS1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 11 Cylinder Head e Tighten the cylinder head bolts following the tightening sequence in the figure ap evince Torque Cylinder Head Bolts 25 N m 2 6 kgf m 19 0 ft Ib CAUTION A torque wrench must be used to assure proper torque Improper tightening of the head bolts may result in warping of the cylinder head 2 CYLINDER e Check and adjust the valve clearance e Install the gaskets and rocker covers Torque Rocker Cover Mounting Bolts 5 9 N m 0 60 kgf m 52 in Ib e Install the other removed parts Push Rod Removal e Set each piston at the T D C of the compression stroke e Remove the rocker covers see Cylinder Head Assembly Removal e Loosen the valve clearance adjusting nuts A e Move the rocker arms B to clear the push rod upper ends e Pull out the push rods NOTE OMark the push rods to reinstall in their original position during a
118. ou want spark plug information for exam ple go to the Periodic Maintenance Chart first The chart tells you how frequently to clean and gap the plug Next use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chapter to find the Spark Plug sec tion Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices A WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not 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 x 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 v
119. ount Parts Call 606 678 9623 or 606 561 4983 STARTER SYSTEM 8 3 Exploded View FH451V FH500V FH531V T1 3 9 N m 0 40 kgf m 35 in lb T2 5 9 N m 0 60 kgf m 52 in lb T3 7 8 N m 0 80 kgf m 69 in lb T4 17 N m 1 7 kgfm 12 ft lb FH541V FH580V T1 3 9 N m 0 40 kgf m 35 mb T2 5 9 N m 0 60 kgf m 52 in lb T3 7 8 N m 0 80 kgf m 69 in Ib T4 17 N m 1 7 kgfm 12 ft lb FH601V FH641V FH661V FH680V FH721V T1 3 9 N m 0 40 kgf m 35 in lb T2 5 9 N m 0 60 kgf m 52 in lb T3 7 8 N m 0 80 kgf m 69 in Ib T4 17 N m 1 7 kgfm 12 ft lb A Recoil Starter Model B Electric Starter Model G Apply grease O Apply engine oil www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 4 STARTER SYSTEM Specifications Standard Item FH451V 500V FH601V 641V Service Limit 531V 541V 580V 661V 680V 721V Electric Starter System Starter Motor Carbon Brush Length with spring boss 12 7 mm 0 500 in 6 4 mm 0 250 in Commutator Groove Depth approx 2 0 mm 0 078 in 0 9 mm 0 035 in Commutator Diameter 31 7 mm 1 250 in 31 1 mm 1 225 in Commutator Runout SE 0 4 mm 0 016 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 STARTER SYSTEM 8 5 Starter System Starter Motor Removal e Remove the mounting bolts A and pull the starter motor B from the engine Starter Motor I
120. ove as many rubber or plastic parts as possi ble from the carburetor before cleaning the carbure tor with a cleaning solution This will prevent from damage or deterioration of the parts The carburetor body has plastic parts that can not be removed Do not use a strong carburetor cleaning solution which could attack these parts instead use a mild high flash point cleaning solu tion safe for plastic parts Do not use wire or any other hard instrument to clean carburetor parts especially jets as they may be damaged e Disassemble the carburetor e Immerse all the carburetor metal parts in a carburetor cleaning solution and clean them e Rinse the parts in water and dry them with compressed air e Do not use rags or paper to dry parts Lint may plug the holes or passages e Blow air through the holes and fuel passages with the compressed air All holes must be open e Assemble the carburetor www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 30 FUEL SYSTEM Carburetor Carburetor Inspection A WARNING Gasoline is extremely flammable and can be explo sive under certain Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Inspect the carburetor body for damage Flange sealing surfaces should be smooth and free of burns and nicks Replace the gasket
121. ow Excessive oil consumption Is compression sufficient Engine backfire Engine knock e High idling R P M e Choke partially closed e Excessively backed off carburetor pilot screw e Worn piston piston rings Stuck piston e Worn cylinder bore e Insufficient cylinder head tightness e Faulty valve seat contact e Plunge up of valve e Wrong valve timing e Broken valve spring e Stuck valve e Plugged oil ring groove e High oil level e Worn valve stems and valve guide e Oil leakage along governor shaft e Oil leakage from oil seal e Oil leakage from mounting surface e Oil leakage from drain plug e Clogged breather valve e Plugged drain back hole in breather chamber e Wrong oil viscosity e Worn piston rings e Stuck piston rings e Worn cylinder bore e Broken piston ring e Loose carburetor or inlet manifold e Loose cylinder head or leaking head gasket e Burned or sticking inlet valve e Faulty ignition coil e Carburetor not properly adjusted e Stale fuel e Excessive carbon deposit in engine e Excessive engine load e Engine overheating e Faulty ignition coil Adjust Open choke Adjust Replace Clean or replace Bore or replace Retighten Lap Adjust valve clearance Adjust Replace Clean or replace Clean Adjust or drain Replace Replace Replace Replace gasket Retighten or replace gasket Clean Clean Correct Replace Clean or replace Bore or replace Repla
122. r of highly flammable liquids do not use gasoline or low flash point solvents www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 8 CAMSHAFT CRANKSHAFT Breather The function of the breather is to create a vacuum in the crankcase which prevents oil from being forced out of the engine through the piston rings oil seals or gaskets A sealed type crankcase emis sion control system is used to eliminate blow by gases The blow by gases are led to the breather chamber through the crankcase and the camshaft Then it is drawn into the clean side of the air cleaner through the cylinder head and the hose and mixed with the clean air flow and subsequently coming into the combustion chamber through the carburetor and the inlet manifold The 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 then returned back to the crankcase cover Standard Type Si Fresh Air 4 Blow by Gas Oil www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 7 9 Breather Heavy Duty Air Cleaner Type for FH541V FH580V OIL lt FRESH AIR Za BLOW BY GAS st Aa RU ieh EN N eee rs i e eal cul e C Z lt ell ATI ea FROM GARBURETOR SH Ki
123. rections x If any part is worn or damaged replace the control panel assembly with a new one e After installation adjust the low idle speed and high idle speed to the specifications see Low Idle Speed and High Idle Speed adjustment in the Periodic Maintenance chap ter e For separate choke type the control panel assembly is as shown in the figure Governor Arm Removal e Remove Control Panel Assembly e Loosen the clamp nut A and take off the governor arm B e Unhook the throttle link rod spring C end loop and clear the throttle link rod lower end D www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 16 FUEL SYSTEM Governor Link Mechanism e For FH541V FH580V model the governor arm is as shown in the figure 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 each other e Loosen the clamp nut F on the governor arm enough to move the governor shaft e Turn the top end of the governor arm counterclockwise to fully open the carburetor G throttle valve and hold it there e Turn the governor shaft counterclockwise fully to the end of its travel e Tighten the clamp nut Torque Governor Arm Clamp Nut 7 8 N m 0 80 kgf m 69 in lb e Be sure the governor shaft extensio
124. rks ft lb Engine Top End Cylinder Head Bolts Valve Clearance Lock Screws Connecting Rod Big End Cap Bolts FH541V FH580V Rocker Arm Bolts Rocker Cover Mounting Bolts Exhaust Pipe Flange Nuts Spark Plugs 6 9 5 9 9 8 28 5 9 15 22 19 0 61 in lb 52 in lb 87 in lb 20 52 in lb 11 16 Lubrication System Engine Drain Plugs Plastic Engine Drain Plug Metal Engine Drain Plug Joint Plastic Engine Drain Plug Joint Metal Oil Pressure Switch Oil Passage Plug Oil Pump Cover Plate Mounting Bolts Oil Filter 6 9 20 17 39 9 8 3 9 5 9 in the text 61 in lb 14 5 12 0 29 87 in lb 35 in lb 52 in lb Camshaft Crankshaft Crankcase Cover Bolts Breather Chamber Cover Bolts Electrical System 25 5 9 19 0 52 in lb Stator Coil Screws 3 4 0 35 30 in lb Flywheel Bolt 56 5 7 41 Fan Housing Bolts 5 9 0 60 52 mb Screen Bolts 5 9 0 60 52 mb Regulator Screws 3 4 0 35 30 mb Ignition Coil Bolts Studs 7 8 0 80 69 in lb Ignition Coil Bolts Bolts 5 9 0 60 52 in lb Starter Motor Mounting Bolts 15 1 5 11 Recoil Starter Mounting Nuts 5 9 0 60 52 mb Recoil Starter Retainer Screw 7 8 0 80 69 in lb Spark Plugs 22 2 2 16 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 6 PERIODIC MAINTENANCE Torque and Locking Agent The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this
125. rnal diameter is less than the service limit re place the crankshaft with a new one PTO Side Crankshaft Journal Diameter A Model Service Limit FH451V 500V 531V 34 90 mm 1 374 in FH541V 580V 34 90 mm 1 374 in FH601V 641V 661V 680V 721V 39 896 mm 1 571 in Flywheel Side Crankshaft Journal Diameter B Model Service Limit FH451V 500V 531V 34 93 mm 1 375 in FH541V 580V 34 93 mm 1 375 in FH601V 641V 661V 680V 721V 39 896 mm 1 571 in Crankpin Resizing The crankpin can be resized to accept 34 5 mm 1 3583 in dia under sized connecting rod If the crankpin is too scored to lap re grind the crankpin See a reliable repair shop for re grinding e Before sending the crankshaft to a reliable repair shop inspect the crankpin for cracks If any crack no matter how small are found the crank shaft cannot be used anymore e The final finishing dimensions are shown in the below ta ble Finishing Dimensional Specifications FH451V FH500V FH531V o E CI 0 Finishing Dimensional Specifications FH541V FH580V A 37 457 37 470 mm 1 4747 1 4752 in B R 2 0 2 4 mm R 0 0787 0 0945 in C 39 50 mm MAX 1 555 in MAX D 33 950 34 050 mm 1 337 1 340 in Finishing Dimensional Specifications FH601V FH641V FH661V FH680V FH721V A 37 457 37 470 mm 1 4747 1 4752 in B R 2 0 2 4 mm R 0 0787
126. rning the pilot screw idle mixture screw out counterclockwise enriches the mixture turning it in clockwise leans the mixture Pilot Fuel Flow gt Pilot System Fuel and Air Supply Fuel Float Main Tank Chamber Jet KCO5126BW3 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 20 FUEL SYSTEM Carburetor Fuel Shut Off Solenoid Valve Electric Starter Model To avoid after firing when stopping the engine a solenoid actuated fuel shut off solenoid valve A is installed in the carburetor bowl The valve shuts off the fuel supply to the valve seat B simultaneously when the switch key turned to the OFF position The valve opens automatically when the switch key is turned to the Run position Low Idle Speed Adjustment e 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 adjusting the idle speed NOTE OThe main jet high altitude kits are available for the equip ment used in the high altitude The main jet numbers are stamped on the en
127. rparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 10 2 TROUBLESHOOTING Engine Troubleshooting Guide If the engine malfunctions check if the way the engine is used is correct If the engine malfunc tions even if the engine is used correctly systematically carry out troubleshooting starting with simple points This chart describes typical troubleshooting procedures Do not unnecessarily disassemble the carburetor the magneto or the engine unless it has been found to be the cause of malfunctioning Remove spark plug and check spark by cranking engine while having the Are spark produced when spark plug is replaced YES e Faulty spark plug Replace NO plug touched against engine block WARNING 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 Are sparks produced when ignition coil is replaced Is compression sufficient Make starting attempts several times then remove spark plug and check electrodes Are they wet Check for plugged fuel line Check for plugged air passage Check float level Check carburetor Check carburetor setting Faulty ignition coil e Wrong air gap e Faulty flywheel No fuel in the tank Entry of dust or air into fuel pipe or filter Plugged air hole in tank cap and fuel pump Plugged fuel line Excessive use
128. rts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 4 LUBRICATION SYSTEM Engine Oil Flow Chart FH451V FH500V FH531V FH601V FH641V FH661V FH680V FH721V www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LUBRICATION SYSTEM 6 5 Engine Oil Flow Chart FH541V FH580V FH601V FH641V FH661V FH680V FH721V On and after 2003 5 product model YY ZAS a KF04001BW5 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 6 LUBRICATION SYSTEM Specifications Item Standard Engine Oil Grade SF SG SH SJ or SL class Viscosity SAE40 SAE30 SAE10W 30 SAE10W 40 or SAE5W 20 Capacity When the oil filter is not 1 5 L 1 6 US qt removed When the oil filter is removed Level Oil Pressure Oil Pressure Switch Detect pressure Screw Oil Filter By pass Valve Opening Pressure 1 7 L 1 8 US qt except FH721V 1 8 L 1 9 Us qt FH721V Operating range grid area on dipstick 241 to 310 kPa 35 to 45 psi Engine oil temperature 120 C 414 to 690 kPa 60 to 100 psi Engine oil temperature 50 C to 60 C 98 kPa 14 2 psi PT 1 8 pipe thread 78 5 117 5 kPa 11 4 17 1 psi Item Oil Pump Inner and outer rotor clearance Outer rotor outside diameter Outer rotor thickness Pump housing inside diameter Pump housing depth Pump shaft outside diameter Pump s
129. s read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation To get the longest life out of your engine e Follow the Periodic Maintenance Chart in the Service Manual eBe alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki en gine parts Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t take shortcuts e Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In preparing this manual we divided the prod uct into its major systems These systems be came the manual s chapters All information for a particular system from adjustment through disassembly and inspection is located in a sin gle chapter The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Table of Contents The Periodic Maintenance Chart is located in the General Information chapter The chart gives a time schedule for required maintenance operations If y
130. s seals www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 3 Before Servicing When pressing in a seal which has manufacturer s marks press it in with the marks facing out Seals should be pressed into place using a suitable driver which contacts evenly with the side of seal until the face of the seal is even with the end of the hole 13 Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips Before a shaft passes through a seal apply a little oil preferably high temperature grease on the lips to reduce rubber to metal friction 14 Circlip Retaining Ring Replace any circlips and retaining rings that were removed with new ones as removal weakens and deforms them When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more 15 Cotter Pin Replace any cotter pins that were removed with new ones as removal deforms and breaks them 16 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film During assembly oil or grease whichever is more suitable should be applied to any rubbing surface which has lost its lubricative film Old grease and dirty oil should be cleaned off Deteriorated grease has lost its lubricative quality and may contain abrasive for
131. se cover see Camshaft Crankshaft chapter e Unscrew the mounting bolts and remove the oil pump parts assembly pump gear pump cover plate pump shaft pins and rotors e Take off the relief valve spring and the ball e Disassemble the pump parts assembly Pin A Pump Gear B Mounting Bolts C Outer Rotor D Inner Rotor E Pump Shaft F Relief Valve Ball G Spring H Pump Cover Plate I 6 mm dia Hole J Oil Pump Relief Valve Installation e Fill the rotor housing with the engine oil for initial lubrica tion e Install the relief valve ball and spring in position then in stall the pump parts assembly in the crankcase cover NOTE OWhen installing the pump parts assembly align the 6 mm dia hole A on the cover plate with center of the relief valve e Install the mounting bolts and tighten them Torque Oil Pump Cover Plate Mounting Bolts 5 9 N m 0 60 kgf m 52 in Ib e Before FH500 A50316 FH531 A07510 model the oil pump and the relief valve are as shown in the figure www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 12 LUBRICATION SYSTEM Oil Pump Relief Valve Oil Pump Relief Valve Inspection e Remove the oil pump see Oil Pump Relief Valve Re moval e Visually inspect the pump gear the outer and inner rotor and the cover plate x If there is any damage or uneven wear replace them with new ones OCheck the clearance A between th
132. ssembly Push Rod Installation e Set each piston at the T D C of the compression stroke e Install the push rods A in their original positions on each cylinder OTo Install the push rod in a correct position on the tappet B insert the push rod so that the end of the push rod is sliding down C along inside wall D of the crankcase and position the push rod end on to the tappet e Check that both inlet and exhaust push rods on each cylinder are at lowest position on the cam lobes E If the piston is not at the T D C of the compression stroke turn the flywheel clockwise one turn 360 and reset each pis ton at the T D C of the compression stroke e Be sure the end of the push rods are correctly seated on the tappets e Tighten the valve clearance adjusting nuts e Check and adjust the valve clearance www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 12 ENGINE TOP END Cylinder Head Push Rod Inspection e Place the push rod on V blocks as far apart as possible and set a dial gauge on the rod at a halfway point between the blocks Turn the rod to measure the runout The dif ference between the highest and the lowest dial readings is the amount of runout x If the runout exceeds the service limit replace the rod with a new one Rocker Arm Push Rod Runout Service Limit 0 5 mm 0 02 in Valve Mechanism Removal Installation e Remove the cylinder head assem
133. sseteadea 3 34 F el P MP lee EE 3 34 Fuel Filter INSP ction ccecceecceccceecceeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeseeeeeeeeeeseeeseeeeseeeeeeeeeeess 3 34 Air Cleaner Standard Ty pe E 3 35 Element HRemoval taent nent aeat nean aenn aea taea naear aeann anneanne 3 35 Element Removal aaa 3 35 Element Installation ri a a 3 35 Element Cleaning and Inspection ccoooiooiconnnnnnnaras nica acc 3 35 Air Cleaner Body Removal ET 3 35 Air Cleaner Body Installation camion dr 3 36 Air Cleaner Heavy Duty Type usos 3 38 Element HRemoval A E T T E E A 3 38 Elemen tInstallation ei a a a a a Mena ged nil vale ness 3 38 Element Cleaning and Inspection c cccceecenceeeeeeeesesscneteeeeneeeeseeeeneneeteneessesececeeeeeeenees 3 38 Air Cleaner ele EE 3 39 Air Cleaner Body iStallation dese idee EE eege ebe ee 3 40 Housing Cap and Body Inspection EE 3 41 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 2 FUEL SYSTEM Exploded View FH451V FH500V FH531V www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 3 Exploded View FH451V FH500V FH531V 1 Pilot Screw 2 Pilot Air Jet 3 Main Air Jet 4 Main Jet 5 Pilot Jet 6 Solenoid Valve 7 Out Vent Tube Before 2003 5 Product model T1 0 7 N m 0 07 kgf m 6 in Ib T2 1 0 N m 0 10 kgf m 9 in Ib T3 1 3 N m 0 13 kgf m 11 in Ib T4 1 7 N
134. t 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 vacuum cap tool www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Coat the valve face sparingly with a fine lapping com pound e Use the vacuum cap tool A to grip the 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 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 Lubrication System Oil Level Inspection e Place the engine on a level surface e Remove the oil filler cap A and wipe its dipstick B with a clean cloth e Insert the dipstick into tube C without screwing it in
135. table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners Threads dia Torque mm N m kgf m ft lb 4 2 0 0 20 17 in lb 5 3 4 0 35 30 in lb 6 5 9 0 60 52 in lb 8 15 1 5 11 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 7 Torque and Locking Agent The following tables lists the tightening torque for the major fasteners and the parts requiring use of a non permanent locking agent or liquid gasket Letters used in the Remarks column mean L Apply a non permanent locking agent to the threads M Apply a molybdenum disulfide lubricant grease or oil to the threads seated surface or washer O Apply oil to the threads seated surface or washer S Tighten the fasteners following the specified sequence SS Apply silicone sealant FH601V FH641V FH661V FH680V FH721V FH601V FH641V FH661V FH680V FH721V Fasteners Torque Remarks N m kgf m ft Ib Fuel System Choke Valve Screw 1 0 0 10 8 9 in lb L Throttle Valve Screws 1 0 0 10 8 9 in lb L Pilot Jet Main Jet Main Jet Plug 19 1 9 14 Main Nozzle Main Air Jet Pilot Air Jet Drain Screw Carburetor 2 0 0 20 18 in lb Ground Lead Screw Carburetor Side Fuel Shut Off Solenoid Valve Carburetor 20 2 0 15 Float Bowl Mounti
136. ter Model Note Portion surrounded by zzz shows KHI procurement parts ur Carburetor Spark Plugs Voltage Regulator w C MT fe e SO e A y d amp Oil Lamp DEN oc 3 4W e dl Fuse 20A E e ES afb c dl e OFF jel RUN foto Battery START obt www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 9 9 Precautions There are a number of important precautions that you must follow when servicing electrical systems Learn and observe all the rules below ODo not reverse the battery cable connections This will burn out the diodes in the electrical parts OAlways check the battery condition before judging other parts of the electrical system A fully charged battery is necessary for conducting accurate electrical system tests ODo not hit the electric parts with a hammer or do not drop the electric parts These may result in the electric parts damage or breakage OTo prevent damage to electrical parts do not disconnect the battery cables or any other electrical connections when the engine switch is on or while the engine is running OBecause of the large amount of current never keep the engine switch turned to the start position when the starter motor will not start or the current may burn out the starter motor windings OTake care not to short the leads that are directly con nected to
137. 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 e Measure the valve head thickness x If the valve head thickness valve margin A is less than the service limit replace the valve with a new one O Valve Head Thickness Service Limit Inlet Exhaust 0 35 mm 0 014 in KEO5007BS1 Valve Stem Runout e Support the valve on 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 Valve Stem Runout Service Limit Inlet Exhaust 0 05 mm 0 002 in Valve Stem Diameter e Measure the diameter of the valve stem A in two direc tions at proper angles at four different positions on the stem x If any single measured valve stem diameter is less than the service limit replace the valve with a new one Valve Stem Diameter Service Limit Inlet 5 95 mm 0 234 in Exhaust 5 93 mm 0 233 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 14 ENGINE TOP END Valves Valve Guide Inside Diameter e Use a small bore gauge or a micrometer to
138. 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 with new ones Piston Ring End Gap Service Limit anata FH500V FH541V Sette Ge 531V FH580V FH721V Top 0 70 mm 0 028 in 0 65 mm 0 026 in Second 0 78 mm 0 031 in Oil 1 05 mm 0 041 in Piston Pin Piston Pin Hole and Connecting Rod Wear e Remove the piston pin e Measure the diameter of the piston pin diameter with a micrometer at several points x If the outside diameter is less than service limit replace the piston pin with a new one Piston Pin Outside Diameter Service Limit 15 96 mm 0 628 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 21 Cylinder Piston e Measure the inside diameter A of the piston pin hole at several points on both side Use a dial bore gauge x If the inside diameter is greater than the service limit re place the piston with a new one Piston Pin Hole Inside Diameter Service Limit 16 08 mm 0 633 in e Measure the inside diameter A of the connecting rod small end at several points Use a dial bore gauge
139. then check the oil level e The oil level should be the operating range A grid area O on the dipstick D x If the oil level is ADD range B add enough engine oil to bring oil level to the operating range A CAUTION Do not add more oil above the operating range Ex cess oil will cause a smoking condition OUse the same type and make of oil that is already in the KFosoogBs1 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 FULL range C drain the excess oil by loosening the drain plug Oil Level Gauge Before 2002 2 produce model E Oil Level Gauge On and after 2002 2 produce model F KFO5010BS1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures Oil Change e Change the oil after first 8 hours of operation Thereafter change oil every 100 hours of operation e Start and warm up the engine to drain the oil easily e Stop the engine e Place the engine on a level surface e Place a suitable container under the engine e Remove the oil drain plug A and drain the oil A WARNING Be careful of hot oil when draining enough to burn you severely It may be hot
140. ther damages Replace them with new ones if necessary www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 16 CAMSHAFT CRANKSHAFT Crankshaft Connecting Rod Connecting Rod Bend Twist e Measure the connecting rod bend OSelect an arbor of the same diameter of the connecting rod big end and insert the arbor through the connecting rod big end OSelect an arbor of the same diameter of the piston pin and at least 100 mm 3 94 in long and insert the arbor through the connecting rod small end OOn a surface plate set the big end arbor on V blocks OWith the connecting rod held vertically use a height gauge to measure the height difference of the small end arbor on the surface plate Using a dial gauge measure the height at two different positions and the distance of the two positions is 100 mm 3 94 in Then determine the connecting rod bent from the measured height differ ences x If connecting rod bend exceeds the service limit replace the connecting rod with a new one Connecting Rod Bend Service Limit 0 15 100 mm 0 006 3 94 in e Measure the connecting rod twist OWith the big end arbor still on the V blocks hold the con nection rod horizontally and measure the amount that the small end arbor difference Using a dial gauge measure the height at tow different positions and the distance of the two positions is 100 mm 3 94 in Then determine the connecting rod twist from t
141. ts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LUBRICATION SYSTEM 6 13 Oil Pump Relief Valve e Before FH500 A50136 FH531 A07510 model the pump housing is as shown in the figure 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 with a new one Pump Shaft Outside Diameter Service Limit 10 923 mm 0 4300 in e Measure the inside diameter A of the pump shaft bear ing in the crankcase cover with an inside micrometer at several points x If the inside diameter is more than the service limit re place the crankcase cover with a new one Pump Shaft Bearing Inside Diameter Service Limit 11 072 mm 0 4359 in e Before FH500 A50136 FH531 A07510 model the pump shaft bearing is as shown in the figure e Visually inspect the relief valve spring the steel ball and the valve seat in the crankcase cover x If any rough spot is found during above inspection wash the valve clean with a high flash point solvent and blow out any foreign particles on 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 www mymowerparts com For Kawasaki Discount Parts Call 606 6
142. ut they must stay within the specified range x If the output voltage is much higher than the specification the regulator is defective or the regulator leads are loose or open x If the output voltage dose not rise as the engine speed increase the regulator is defective orthe alternator output is insufficient for the loads Regulated Output Voltage Battery Voltage to 15 VDC www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 9 14 ELECTRICAL SYSTEM Charging System Stator Coil Resistance e Disconnect the connector A e Measure the stator coil resistance Electric Starter Model OConnect an ohmmeter between stator pins B Stator Coil Resistance Electric Starter Model 0 01 to 0 1 Q Recoil Starter Model with Electric Clutch OConnect an ohmmeter between the stator pin and engine body Stator Coil Resistance Recoil Starter Model with Electric Clutch 4 4 to 150 x If the measured value is not within the specification re place the stator coil with a new one x If the coil has normal resistance but the voltage inspec tion shows the alternator to be defective the flywheel magnets have probably weakened and the flywheel must be replaced e Check for continuity between each stator pin and ground There should be no continuity infinite ohm x If the stator coil fails any of these tests replace the coil with a new one Unregulated Stator Output e Disconnect the connector
143. uts and screws Check battery electrolyte level e Clean air cleaner foam element 1 Clean air cleaner paper element 1 Clean cylinder and cylinder head fins 1 Tighten nut and screws Change engine oil e Clean and re gap spark plugs Change oil filter Change air cleaner paper element 1 Replace air cleaner element Heavy duty air cleaner model 1 Check and adjust valve O clearance Clean and lap valve seating A surface Clean combustion chambers e 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 Periodic Maintenance Chart FH601V FH641V FH661V FH680V FH721V INTERVAL Every Every Every Every Every OPERATION First Every Every 8 hr 25 hr 50 hr Check and clean air inlet screen Check and add engine oil Check for fuel and oil leakage Check for loose or lost nuts and screws Check battery electrolyte level Clean air cleaner foam element 1 Clean air cleaner paper element 1 Replace air cleaner paper element 1 Replace air cleaner primary element Heavy duty air cleaner model 1 Clean cylinder and cylinder hea
144. ve the clip e Unwind the spring tension slowly NOTE ODo not wedge the rope between the reel and case e Remove Screw A Washer B Retainer C Center Spring D Washer E Pawls F Return Springs G A WARNING When removing the reel A be careful that the re coil spring B under the reel does not fly loose and cause injury The spring is under great pressure NOTE OThere should be no spring tension on the reel when removing it If tension is felt push the reel back into place and gently wiggle it until the reel can be easily removed e Slowly lift the reel straight up out of the case C A WARNING If the recoil spring cassette is sticking with the reel be careful that the cassette does not drop Be careful that the recoil spring does not fly loose from the cassette and cause injury The spring is under great pressure e Slowly lift the recoil spring cassette straight up out of the case or reel www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 10 STARTER SYSTEM Starter System If necessary remove the recoil spring A as follows OPlace the cassette B facing down in a suitable container OTap the cassette B to remove the recoil spring Recoil Starter Assembly A WARNING Wear gloves during the recoil spring installation to avoid injury The recoil spring must be assembled with great pressure e Lightly grease the reco
145. w at this point OTurn the pilot screw clockwise and count the number of turns until screw is gently seated in the pilot passage Record the number of turns needed to close the screw OTurn out the pilot screw to replace it with a new one Olnstall the new pilot screw until the screw is gently seated Then open the screw the same number of turns as recorded prior to removal OAlign the limiter with the mark on the carburetor body to install taking care not to turn the pilot screw e Install the choke valve and throttle valve on the shaft as the outside mark of them facing outside e Drive the float pin into the carburetor body The big diam eter side of the float pin must face the engine flange side e The fuel inlet valve seat is pressed into the carburetor body and is not replaceable e Assemble carburetor parts with recommended tightening torque see Exploded View kcosos0Bsa o 1 Limiter 21 Float Bowl 2 Pilot Screw 22 Gasket 3 Spring 23 Bolt Other than Solenoid 4 Low Idle Speed Valve Type Screw 24 Gasket 5 Spring 25 Solenoid Valve Electric 6 Seal Starter Model 7 Ring 26 Drain Screw 8 Throttle Shaft 27 Gasket 9 Throttle Valve 28 Float Pin 10 Screws 29 Snap Ring 11 Pilot Jet 30 Float Valve 12 Screw 31 Main Air Jet 13 Choke Valve 32 Air Jet 14 Choke Shaft 33 Washer 15 Spring 34 E Type Circlip 16 Collar 35 Cap 17 Main jet 36 Ground Lead Electric 18 Float Starter Mo
146. wing ORemove the carburetor see Carburetor Removal OUnscrew the main jet plugs C and take off the main jet plugs and gaskets OMake sure that L L or R R mark on the float shows the main jet position OUsing a proper standard tip screwdriver carefully replace the main jet D with a new one for expected altitude OTighten the main jet to the specified torque see Carbure tor Disassembly Assembly Olnstall the gasket and the main jet plug Torque Main Jet Plug 19 N m 1 9 kgf m 14 ft Ib 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 ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove Air Cleaner and Related Parts see Air Cleaner Body e Turn the fuel shut off valve to the OFF position e Drain the carburetor e Disconnect the fuel tube at the fuel inlet joint A of the carburetor e For Electric Starter model disconnect the solenoid valve lead terminal and remove the ground terminal e Unhook the throttle link spring B at the throttle shaft lever top end C with a long nose plier e Unhook the throttle D and choke link rods E at the top ends of
147. y during honing using an inside micrometer CAUTION Stop the drill press before measuring and remove the hone from the cylinder NOTE OThe finished cylinder bore surface should not be smooth but have a 40 to 60 degree crosshatch pat tern e Hone the cylinder until it is about 0 007 to 0 009 mm 0 0003 to 0 0004 in large to allow for shrinkage when the cylinder cools NOTE ODo not use gasoline kerosene or commercial solvent to clean the cylinder bore These fluids only wash all the oil from the cylinder wall They do not remove the metal particles produced during honing e Clean the cylinder thoroughly Using soap warm water and clean cloth clean the cylinder wall A clean white cloth should not show soil from the cylinder wall e Dry the cylinder and coat with engine oil CAUTION The cylinder must be thoroughly cleaned after hon ing to eliminate all grit www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 24 ENGINE TOP END Muffler Exhaust Pipe Installation Muffler Exhaust Pipe Removal Early Models e Loosen the clamp nut A e Remove the bolt B on the muffler bracket and take off the muffler Late Models e Loosen the clamp nut A e Remove the bolts B on the muffler bracket and take off the muffler C e Unscrew the exhaust pipe flange nuts A and remove the exhaust pipe B with the pipe cover C Use a penetrative oil if n

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