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Service Manual

1. e Feed ends of the line out through the eyelets A on the drum B CAUTION Keep line as tight as possible and do not let it slip under the spool into the drum e Align the peg A on the drum with the slots in the spool and push the spool into the drum e Hold the drum B firmly twist the spool C sharply in direction shown until the peg A goes into the hole D with a click and locks the spool C to the drum B e Cut the lines to about 100 mm 4 in long www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 14 POWER TRAIN Cutting Head Australian Model Disassembly e Turn the set screw A in accordance with the arrow B marked at the bottom of the head e Remove the set screw to disassemble the cutting head as shown A Retainer B Slider C Return Spring D Spool E Line F Case G Set Screw Reassembly e Use one line 6 m 20 ft long e Turn down the line in two in order that one side is about 150 mm Bending point 5 90 in longer than the other side Line e Hitch the line to the hook on the spool at its turned point Wind both ends of the line on the spool at the same time CAUTION Wind tightly and evenly from side to side and do not twist the line ignore the ridge e After the line was wound have both sides of the line caught in the notches in order to pull both ends of the line out of the notches
2. CAUTION Do not apply too much grease to the drive shaft Never pump grease into the guard tube 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 ENGINE 3 1 Table of Contents Clutch and Fuera ld ctas 3 2 Removal dd at EE EE E IEE EREA 3 2 installation not aa ERA EA o a a dos 3 2 Air Cleaner carburetor and Mulffler cccconncccoocococonaconononononanononnnononononnnnnnnnnncnnnnnnnnnnnnnnnnannnnnnnnnnrnnnnnnnnnrnnnnnnnnnnnnnnnnnannnnns 3 3 ataO E NEEE E EA N E NEE E EAE OE A AE E AAE A N A ica 3 3 VOSENN A REAN A O cn 3 3 Recoil Starter Shroud Fan Housing and Ignition COil oooonncnnicccinnccnnnccnnncconnnccnonrnconacnnnnnn corn ccnnn cnc cnn 3 4 RM ui E r E A N A R A R E 3 4 WASTE FEN ONT OEE EE E EEEN E E E E N AEE E E E EEA 3 4 Ignition Coil NSPE ONE 2 tt ii 3 5 Flywheel and CyliMGer EE EE E EE E EE E E A E 3 6 Removal taa aa sand aa A AA E 3 6 PEELE g EE E E E E a a 3 7 Piston and Piston RING crucis A ae ati a aaa 3 8 Rem Mutis atada ita id das 3 8 INSTA 1 a a Eee 3 8 Crankcase and Crankshaft KBL23A KBO26A KB034A KBO43A KBOABA coooococccccccococcconnnoooonocononononononnnnnnnnnnnnnnnononns 3 9 Removal iia A A AAA E E E aa 3 9 A sien da reseed Seca ves sWesaeee deve ea wee lava nau A e Ses evawiancacaaad
3. Main diaphragm Reassembly Before assembly clean removed parts and the body with suitable detergent and use compressed air to dry e Reassembly is the reverse of disassembly Metering Chamber Adjustment Control lever e Push tip of the control lever lightly to check smooth movement of the Body surface 0 08 0 09m control lever e After installation check control lever height proper height is as shown but if the lever and the plate are on much the same surface lever height shows no problem in use Use ruler as a simple method to check control lever height as shown If necessary adjust by bending the control lever slightly CAUTION Excessively bending the lever to the body down side as shown results in faulty acceleration and the engine stops during operation Bending the lever to the opposite side up Control lever side as shown results in excessive fuel consumption and impossibility in starting due to overflow Plate www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 12 SUPPLEMENT Piston Valve Diaphragm Type Carburetor KBLI33A KBLI43A KBLi48A Main Adjust Screw Adjustment e Turn the main adjust screw slowly clockwise until it stops at full closure and then turn it out 1 1 8 turns for KBLI33A or 1 1 2 1 2 turns for KBH43A and KBH48A CAUTION Turn the screw slowly because overturning tightening causes Main adjust screw defor
4. e Pull the complete engine out of the guard tube A e Withdraw the drive shaft B from the guard tube A www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 4 POWER TRAIN Complete Engine Complete Engine Installation KBL23A KBO26A e Installation is the reverse of removal Note the following points O Have the end of the guard tube A coming home to the bottom of the clutch housing B O Have the spline end of the drive shaft C meshing with that of the clutch drum s stub D E M AS El do SS NA Xx O Tighten the clamp screw C to bring imaginary planes A A and B B into line See Tightening Torque Table www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 POWER TRAIN 2 5 Complete Engine Complete Engine Installation KBI33A KBLI34A KBLI43A KBOI48A e Installation is the reverse of removal Note the following points O Have the end of the guard tube A coming home to the bottom of the clutch housing B O Have the spline end of the drive shaft C meshing with that of the clutch drum s stub D O Align the hole A of the clutch housing C with that of the guard tube to tighten the alignment screw B and then tighten the clamp screw D to the specified torque www mymowertrparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983
5. Removal e Unscrew the shroud mounting screw to remove the shroud e Unscrew the air cleaner mounting screws A to remove the air cleaner assembly B e Unscrew the two carburetor mounting screws C to remove the carburetor together with the gaskets D F and the insulator E NOTE Do not remove the carburetor if not needed e Unscrew the muffler cover mounting screws G to remove the muffler cover H e Unscrew the four muffler mounting screws J to remove the muffler body K and the baffle plate L KBL23A KB26A e Unscrew the two flange bolts M to remove the muffler body complete N together with the gasket P and the flange Q NOTE In ordinary circumstances there is no need to remove the muffler body complete N out of the cylinder KBLI43A KBL48A Installation e Installation is the reverse of removal e Use new gaskets e If the insulator A is removed fit the screw to round seat and nuts KBL43A KBL48A D to the hexagonal seats in the insulator A and put the insulator gasket B onto screw ends as shown then install the insulator on the cylinder C with the screws O Each pulse hole must align www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 4 ENGINE Recoil Starter Shroud Fan Housing and Ignition Coil Removal KBCI33A e Remove the four mounting screws A to remove the recoil starter B e Release the
6. 2 6 POWER TRAIN Complete Engine Throttle Cable Free Play Adjustment KBU33A KBLI43A KBU48A e After the throttle cable A was connected in the coupler B place the throttle lever at its idle position to adjust the nut C in order that the end A of the throttle outer cable can come to the position specified in the figure with the cable related level e Lock the adjusting nut C by turning the locking nut D Throttle Cable Free Play Adjustment KBL23A KBLI26A KBO34A e After the throttle cable A was connected to the carburetor place the throttle lever at its idle position to adjust free play of the throttle cable A to about 1 mm 0 04 in long by turning the adjuster B with the loop handle installed in place e Tighten the locknut C to keep the adjuster B from loosening Free play www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 POWER TRAIN 2 7 Gear Case Removal e Remove the alignment screw A keeping the complete gear case from turning e Release the clamp screw B all the way e Pull the complete gear case C out of the guard tube D e Release its clamp screw to remove the gear case cover E Installation e Installation is the reverse of removal e Align a hole A of the gear case C with that of the drive tube D to tighten the alignment screw A and then tighten the clamp screw B to the specified
7. Priming Pump Priming Pump Check valve Fuel Outlet Main Check Valve Throttle Valve Jet Needle _ Q e o do cd NON A www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 14 SUPPLEMENT Piston Valve Diaphragm Type Carburetor KBLI33A KBL143A KBLi48A Choke System Use the choke lever to fully close the choke valve open the throttle lever half turn the engine switch to ON and pull the recoil starter rapidly until the engine fires At this time intake negative pressure increases by choking more fuel flows from the needle jet and rich nanely containing extra fuel air fuel mixture suitable for starting the engine is sucked into the engine cylinder After the engine starts open the choke valve gradually to full open position In tense heat or when the engine is warm open the choke valve half or fully Idling System At this time throttle valve position is at the lowest in the carburetor and opening of the valve becomes minimum The minimum opening of the throttle valve is decided by adjusting the throttle stop screw and fuel flow rate is controlled by clearance between the needle jet and the jet needle The slot on bottom surface of the throttle valve regulates the negative pressure on the needle jet to give fuel flow appropriate for idling Air fuel imixfure Metering chamber Idling pressure control slot y N Thrott
8. e Remove the priming pump cover 20 the priming pump 19 the air purge body 18 the main diaphragm 18 the gasket 16 the pump body 15 the pump diaphragm 8 and the pump gasket 7 in that order e Remove the main jet 6 and the O ring 5 from the carburetor body 4 CAUTION Do not remove the main nozzle 22 as it is press fitted If much dirt is found inside the carburetor especially on the inlet screen clean the fuel tank inside and replace the fuel filter Reassembly Before reassembly clean removed parts and the body with suitable detergent and use compressed air to dry e Reassembly is the reverse of removal www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 SUPPLEMENT 5 5 Rotary Valve Diaphragm Type Carburetor KBL23A KBL126A KBLI34A Inspection and Adjustment e Clean the carburetor with cleaning oil and apply air e Check to see that no dirt or corrosion is found in the main jet If dirt is found clean and apply air If corrosion is found replace the main jet with new one CAUTION When replacing the main jet be sure to replace with a jet with the same number e As to the gaskets check to see if no deformation or damage is found If deformation or damage is found replace them with new ones e Check the pump diaphragm to see if no damage or hardening is found Check the inlet check valve and the outlet che
9. starting the return pipe in side spite of several priming operation Broken tube at inlet side Air leakage from joint portion of fuel tube at inlet side Adhesion of dust to check valve of priming pump Broken check valve of priming pump or damaged seat surface of pump cover Air leakage from fitting area of priming pump Broken priming pump Air leakage from main check valve Loose main diaphragm cover Broken main diaphragm Broken main diaphragm gasket Replace the tube Fit fuel tube to the joint If not good replace the tube Disassemble and clean parts Replace the check valve or the pump cover Retighten screws to priming pump plate Replace the pump Disassemble and clean the check valve If not good replace the main check valve and the plate Retighten screws to the diaphragm cover Replace the main diaphragm Replace the gasket Fuel drains into the return pipe by priming operation but engine does not start After starting engine revolution does not continue Choke valve not closed Air entering engine through the fitting portion of carburetor Main adjust screw not adjusted properly Clogged needle jet Overflow of fuel from needle jet to the venturi of carburetor Choke valve closed after starting Clogged pulse passage Improper height of control lever Close choke valve Retighten the fitting bolts of the carb
10. 561 4983 2 12 POWER TRAIN Cutting Head Cutting Head Installation The nylon cord cutter head A has a left handed mounting thread e Turn the brushcutter upside down on the ground with its cutting tool shaft B upward e Aligning the hole of the holder C with the hole F on the gear box insert a wrench provided into the gear case to keep the cutting tool shaft B from turning O Take care that the cover G is centered by putting it onto socket and spigot at between the holder C and the holder D e Tighten the nylon cord cutter head A by turning itself counterclock wise with both hands as much as possible www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 POWER TRAIN 2 13 WES ik Q Cutting Head except Australian Model Disassembly Locked e Do not push the spool A in Hold the drum B firmly and turn the spool A clockwise to take up slack then twist with a hard snap until plastic peg C is between the holdes D amp E e Pull the spool A out of the drum B Reassembly e Use one line 6 m 20 ft long e Thread end of the line A through the hole B on the spool C and pull through until the line A is the same length on both sides of the hole B e Wind both ends of the line A counterclockwise at same time CAUTION Wind tightly and evenly from side to side and do not twist the line ignore the ridge
11. F to pull the cap G out of the exhaust outlet together with the gasket H e Draw the net J of the arrester out of the muffler assembly M through the exhaust outlet Installation e Installation is the reverse of removal CAUTION Do not reuse the gaskets E and H and the tapping screw F Cleaning Do not use gasoline or low flash point solvents for cleaning purposes A fire or explosion could result e Clean the net J of the arrester by soaking it in a high flash point solvent and dry with compressed air e f the net J of the arrester is still clogged after soaking gently clean it with a fine wire blush in the solvent and dry with compressed air e Reinstall the net J of the arrester www mymowerparts com
12. Ignition coil air gap 0 3 to 0 5 mm 0 4 to 0 5mm 0 3 to 0 5 mm 0 011 to 0 019 in 0 015 to 0 011 to 0 019 in 0 019 in ignition timing 25 B T D C 7000 rpm 17 21 2 3 11 2 1 2 about 13 to 17 grams Gear ratio Jet needle clip location Main adjust screw turning out Gear case grease capacity full case 14 19 2 3 1 1 2 1 2 about 8 to 10 grams www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 POWER TRAIN 2 1 Power Train Table of Contents Complete ENGin Gis cti dni eta 2 2 Complete Engine Removal KBL23A KBLI2Z6A KBLIQ4A eeeeeeceeeceeeeeeneeeeeeneeeaeeeaeeceeeaeesaeesaeeseesaeeseeesieesieeteneeaees 2 2 Complete Engine Removal KBLI33A KBLI34A KBLI43A KBLI48A seeeeceeseeeneeeeeeeeeeeneeeaeeeaeetaeeeaeesaeeseeeneeeeneeaees 2 3 Complete Engine Installation KBL23A KBLI2Z6A ececeeeeeneeeneeeneeeaeeeeeeeaeeeaeseaeeeaeeeaeseaeesaeeeaeeeaeeeeeeaeeseesieeentenaes 2 4 Complete Engine Installation KBL33A KBLI34A KBLI43A KBLI48 A eeceeeceeeeeeneeeeeeeeeeeeeeeeeeeaeeseeeeeeeeseeseneeeaeeaes 2 5 Throttle Cable Free Play Adjustment KBLI33A KBLI43A KBLI48A ce eeeeeeceeneeeseeeneeeeeeaeeeeeeeeeeeseeeaeeeeeeeeeaeeeas 2 6 Throttle Cable Free Play Adjustment KBL23A KBIOD26A KBOB4
13. Limit KBL23A KBO33A KBLI34A 43A KBLI48A Remarks Cylinder bore 32 1 32 8 37 1 44 1 1 263 1 291 1 461 1 736 Replace if over Piston to cylinder 0 15 Replace if over clearance Piston ring to groove E 0 17 Replace if over clearance Piston ring end gap A 0 7 Replace if over Piston to piston pin gt 0 1 Replace if over clearance Connecting rod big end z z 0 5 Replace if over axail play Connecting rod big end 0 15 Replace if over radial play Piston pin to needle i E 0 15 Replace if over bearing radial play Ball bearing axial play i 0 5 Replace if over Crankshaft axial play 0 05 0 295 Adjust if over does not include that of ball bearings www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 1 12 GENERAL INFORMATION Setting Table Setting Table The engine speed at which the clutch engages Max engine speed rpm Standard Setting KBL23A about 4000 rpm at 4 0 N m 0 4 kg m of drag torque about 3800 rpm at 4 0 N m 0 4 kg m of drag torque Different depending on matching machine KBLI48A about 3500 rpm at 4 0 N m 0 4 kg m of drag torque Idling speed rpm 3000 200 rpm
14. air cleaner Clean aircleaner and exhaust excess fuel from cylinder On removing spark plug Faulty fuel Mixture of water into fuel Change fuel moisture condensed on spark plug electrodes Deterioration in fuel because of poor long term storage Use of fuel other than designated Change fuel Change fuel Make spark check No spark but spark appears on spark plug replaced No spark in any spark plug but spark appears when the end of high tension cord is touched to engine block Faulty spark plug Faulty plug cap Electrodes are burned and damaged to cause too wide gap Much carbon bridging electrodes gap Small foreign matter being caught between electrodes Faulty insulation of electroes Faulty contacting at spark plug cap Correct gap or replace Clean or replace Clean Clean or replace spark plug Remove plug cap and connect terminal again www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING 4 3 Engine Troubleshooting Symptom Cause Remedy No spark or very week spark at the end of high tension cord Spark appears when stop Faulty stop switch Stop switch lead wire is Correct switch wire is jammed disconnected at Short circuit in stop switch Replace connector No spark appeas even Slow recoil starter Recoil starter revolution is Pull recoil starter rope when stop switch wire is revolution low
15. clip to the proper position 2nd stage of jet needle Change the clip to upper position of jet needle If not good replace the jet needle and the carburetor body eAdjust the control lever height properly Remove and clean the tube Disassemble and clean the fuel pump Adjust the screw properly Disassemble and clean Disassemble and clean the check valve portion eAdjust the control lever height properly Insert the clip to the proper position 2nd stage of jet needle Unstable revolution at high speed When throttle valve is returned to idling position engine stops Clogged air filter Dust clogging in or air entering fuel tube Air entering engine through the fitting portion of carburetor Fuel passage or pulse passage of fuel pump is clogged Main adjust screw not adjusted properly Clogged needle jet Clogged main check valve Improper height of control lever Air entering engine through the fitting portion of carburetor Too low idling revolution Clogged main check valve Clogged needle jet Improper position of clip to jet needle Worn jet needle or needle jet Improper height of control lever Clean the filter Remove and clean or replace the tube Retighten the fitting bolts of the carburetor or replace the fitting gasket Disassemble and clean the fuel pump eAdjust the screw properly Disassemble and clean Disassemble and c
16. pipe 21 from the priming pump check valve 20 which causes negative pressure inside the metering chamber 13 and the needle valve 7 opens Then fuel from the fuel tanks is sucked into the metering chamber through the inlet cheek valve 4 and then into the priming pump And excessive fuel is discharged from the overflow pipe This operation is called Priming operation at starting Non emission type Engine Pulse Passage 18 Priming Pump Fuel Pump Diaphragm 19 Main Check Valve Fuel Inlet 20 Priming Pump Check Valve Inlet Check Valve 21 Overflow Pipe Outlet Check Valve 22 Idle Adjust Screw Inlet Screen Needle Valve Throttle Valve Air Vent Main Diaphragm On DO PR WO ND a o Control Lever N Valve Spring Metering Chamber Lead Cam Idle Needle Pin Main Jet Main Nozzle oo a a i NO nO Aa W emission type www mymowertrparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 SUPPLEMENT 5 3 Rotary Valve Diaphragm Type Carburetor KBL23A KBLI26A KBLI34A Fuel Pump System After starting the engine part of pressure change inside the crankcase caused by engine revolution is transmitted to the pump diaphragm 2 through the engine pulse passage 1 which deforms the pump diaphragm and it starts reciprocating motion Namely fuel is sucked from the tank into the carburetor under
17. pressure by volume change due to the pump diaphragm s reciprocating motion and the inlet 4 and the outlet check valves 5 function Metering Chamber System The main diaphragm 10 forming the metering chamber senses inside fuel pressure change of the metering chamber 13 which occurs in accordance with the engine revolution change as vertical motion And it works to keep a uniform pressure equivalent to the fuel surface of a float type carburetor inside the metering chamber by opening and closing the needle valve 7 Fuel in the metering chamber is drawn by negative pressure in the venturi blown out from the main nozzle 17 mixed with air passed through the venturi and sucked into the engine When the engine stops negative pressure in the venturi becomes zero the control lever 11 is pushed up with the valve spring 12 and the needle valve 7 closes Then fuel flow stops and overflow is prevented www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 4 SUPPLEMENT Rotary Valve Diaphragm Type Carburetor KBL23A KB 126A KB 134A Disassembly Before disassembling clean the carburetor with cleaning oil so that no dirt enters the carburetor e Remove 2 throttle collar screws 1 to remove the throttle valve assembly 3 from the carburetor body 4 CAUTION Do not disassemble the throttle valve assembly 3 e Remove 4 pump cover screws 21 with the priming pump 19 side upward
18. special instruc tions or procedures which if not strictly ob served could result in damage 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 information NOTE o This note symbol indicates points of particular in terest for more efficient and convenient operation e Indicates a procedural step or work to be done O Indicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a WARNING CAUTION or NOTE Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub step it follows www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 1 General Information Table of Contents Before Servicing 24 8 ideas iti sade hii Ane et Mie iinet ae ee Aes eek ia ieee 1 2 Idling SPCC A O TT 1 4 General Specifications asen a A OA ee 1 5 Periodic Maintenance Chat scicoicit ad dra 1 8 Tightening Tor QUe veia gees geet ieee wee ee ibe a ad eR atin Ldn ead A eee 1 9 Clearance Table ste 1 11 Setting Table ii a paa ae 1 12 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 careful read the applicable section to eli
19. starting pulley locknut C counterclockwise to remove it together with the washer D e Remove the starting pulley E by turning itself counterclockwise e Remove the spark plug cup F out of the spark plug G e Remove the plug cup F out of the high tension cord M e Remove the shroud H e Disconnect the ignition lead wire J e Remove the fan housing K e Remove the ignition coil L KBL23A KBLI26A KB_I43A KBLi48A Installation ignition coil e Installation is the reverse of removal e Adjust the ignition coil air gap to the specified value Ignition Coil Air Gap Specified Air gap KBL23A KBL26A KBL134A KBL143A KBL48A Kay 0 3 to 0 5 mm 0 011 to 0 019 in ea KBU33A q 0 4 to 0 5 mm 0 015 to 0 019 in Flywheel www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE 3 5 Recoil Starter Shroud Fan Housing and Ignition Coil e Install the starting pulley to the crankshaft by turning clockwise Rotating direction seen from recoil side O The recoil pawl must be fitted on the pulley as shown a l Recoil pawl Ignition Coil Inspection KBL23A KBLI26A KBL134A The ignition coil has been integrated with an igniter being solid state e Use the Kawasaki hand tester P N 57001 1394 resistance value may vary with individual meters e Set the Kawasaki hand tester to the specified range e Connect
20. which brand new parts or systems have Service Limits indicate the usable limits If the measurement shows excessive wear or deteriorated performance replace the damaged parts www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 1 4 GENERAL INFORMATION Idling Speed Idling Speed Adjustment KBL23A KBL126A KBL134A e Start the engine and leave it running at idling speed to warm it up thoroughly e l the engine stops while idling turn the throttle stop screw A clockwise until the cutting head or the cutting blade begins to rotate Then back off one half turn The cutting head or the cutting blade must not rotate e If the cutting head or the cutting blade rotates when the engine is idling turn the throttle stop screw A counterclockwise until the cutting head or the cutting blade stops rotating and then turn the throttle stop screw A another one half turn KBLI33A www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 5 General Specifications Model KBL23A KBH26A KBL26A Handle type Loop handle Double handles Loop handle Engie Type Forced air cooled 2 stroke horizontal shaft gasoline engine Displacement 22 5 25 4 25 4 ml cu in 1 37 1 55 1 55 Carburetor Diaphragm type Ignition Solid state ignition Spark plug NGK BPMR6A Starter Recoil starter Clutch Automatic ce
21. 0 50 35 44 in lb Clutch Housing Clamp Screw M5 3 5 4 0 0 35 0 40 31 35 in lb Clutch Housing MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb Cutter Blade Mounting Nut M8 13 15 1 30 1 50 8 9 11 Tightening Torque KBLI33A Fasteners Nm e ftlb Remarks Air Cleaner Assy MTGS 1 7 2 0 0 35 0 40 15 18 in lb Ignition Coil MTGS 3 5 4 0 0 35 0 40 31 35 in lb LA Recoil Starter MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb LA Crankcase Connecting Screw M5 3 5 4 0 0 35 0 40 31 35 in lb LA Head Shroud MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb LA Carburetor MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb Insulator MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb LA Fuel Tank MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb LA Muffler MTGS 3 9 4 4 0 40 0 45 35 39 in lb LA Muffler Cover MTGS 3 5 4 0 0 35 0 40 31 35 in lb LA Cylinder MTGS 3 5 4 0 0 35 0 40 31 35 in lb LA Clutch Shoe MTGS 14 16 1 40 1 60 10 12 LA Flywheel Nut 14 16 1 40 1 60 10 12 Starter Pulley Nut M8 14 16 1 40 1 60 10 12 Starter Pulley M8 10 12 1 00 1 20 89 106 in lb Spark Plug M14 12 17 1 20 1 70 8 9 13 in lb Gear Case Clamp Screw M6 8 0 10 0 80 1 00 71 89 in lb Gear Case Alignment Screw M5 3 5 4 0 0 35 0 40 31 35 in lb Grease Hole Bolt M6 4 0 5 0 0 40 0 50 15 18 in lb Clutch Housing Alignment Screw M5 3 5 4 0 0 35 0 40 31 35 in lb Clutch Housing MTGS M6 8 0 10 0 80 1 00 71 89 in lb Cutting Tool Guard MTGS M5 3 5 4 0 0 3
22. 5 0 40 31 35 in lb www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 1 10 GENERAL INFORMATION Tightening Torque Tightening Torque KBLI34A Fasteners alee Nom aoe tib Remarks M5 2 0 2 5 0 20 0 25 18 22 in lb Ignition Coil MTGS M4 2 0 2 5 0 20 0 25 18 22 in lb M4 1 7 2 0 0 17 0 20 15 18 in lb Crankcase Connecting Screw M5 3 5 4 0 0 35 0 40 31 35 in lb LA LG Engine Shroud MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb Carburetor Air Cleaner Case MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb Insulator MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb Fuel Tank MTGS Crankcase side M5 3 5 4 0 0 35 0 40 31 35 in lb Fuel Tank MTGS Recoil Starter side M5 20 25 0 20 0 25 18 22 in lb Muffler MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb Muffler Cover MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb Cylinder MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb Clutch Shoe MTGS M8 14 16 1 4 1 6 10 12 LA Flywheel Nut M8 14 16 1 4 1 6 10 12 Starter Pulley Nut M8 14 16 1 40 1 60 10 12 Starter Pulley M8 10 12 1 00 1 20 7 2 8 7 Spark Plug M14 12 17 1 20 1 70 8 9 13 Gear Case Clamp Screw M6 8 10 0 8 1 0 6 0 7 4 Gear Case Alignment Screw M5 3 5 4 0 0 35 0 40 31 35 in lb Grease Hole Bolt M6 4 0 5 0 0 40 0 50 35 44 in lb Clutch Housin
23. 8 GENERAL INFORMATION Periodic Maintenance Chart AWARNING Accidental engine starting can cause injury Always remove the spark plug cap before servicing the engine to prevent accidental starting Interval Maintenance Daily First Every Every Every 20 hours 20 hours 50 hours 100 hours Check and replenish fuel Check for fuel leakage Check bolts nuts and screws for looseness and loss Check throttle lever operation Check engine switch operation Check guard assembly condition Check hook of shoulder harness condition Clean fuel filter Clean air filter element Tighten bolts nuts and screws Clean spark plug and adjust electrode gap Remove dust and dirt from cylinder fins ooo nn Remove carbon deposits on piston head and inside cylinder Remove carbon deposits in the exhaust pipe of muffler Check gear case assembly lubrication Check drive shaft lubricaion Check the sliding portion of crankshaft e connecting rod etc Fuel tube It is recommended to replace every 3 years NOTE o The service intervals indicated are to be used as a guide Service to be performed more frequently as necessary by operating condition www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 9 Tightening Torque The following tables list the tightening torque for the major fasteners and the parts requiring
24. A eeeeceeeceeeeeeeeeeeeeeneeeeeeeeetaeeeeeeeeteeeeeeeneeeaeee 2 6 Gat Cases A E ETA T ATTAT 2 7 PRemovallss E T AT E E oda 2 7 OS a di 2 7 Disassembly KBL23A KBLI26A cocoonoconcconcconocconocnnnnnncrnncnnnc ner 2 8 Disassembly KBLI33A KBLI34A KBLI43A KBLI48A coooooonccocccoonconncnnnonononncnn conc cnn rre nr nr rre nene 2 9 Reassembly KBL23A KBEJ2GA iis arahera dr ita tao eet nate 2 10 Gear Case Lubrication n la bi 2 10 G tting Blad iinan s eatae anaa a aa EE Aea a daaa Aa aaa need tape etait aeaa 2 11 Cutting Blade Installation irrin a a Medina NE nea 2 11 Cutting Head tii A EAE 2 12 Cutting Head Installation te tae ai eed 2 12 Cutting Head except Australian Model ee cecesceesesseeeseeceeecseeeseecaeesseeeseecseesseecseesseesseesseecseesseeeseecseesaeesseesseesaeeeneetanes 2 13 Disassembly aceasta Ads 2 13 E el E OO es 2 13 Cutting Head Australian Model ee cescesceeseeeseeeseeceeeeaeeeaeecseeeseesaeesseecaeesaeesseeeaeesseecseesaeesaeesseeeaeesaeeseeeaeeeeeesineseeenes 2 14 Disassembly asista dd ino l a 2 14 Reassembly a ic ichshamhthee edn ii A A ai 2 14 Operation Cheka de 2 16 Gear Case Servite iii a a 2 16 Drivo Shaft SOI ua dad 2 17 www mymowertrparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 2 POWER TRAIN Complete Engine Complete Engine Removal KBL23A KBLI26A KBLI34A The power train has been designed to have friction enough between the clutch hous
25. After the mowing head was assembled check if the mowing head operates correctly N O Tap the ground 2 or 3 times with the mowing head if the mowing head clicks O Pull both ends of the line out of the mowing head if both ends of the line can be pulled out of the mowing head e Pull both ends of the line out of the mowing head to remove slack and then cut them 120 to 150 mm 4 72 to 5 90 in long ad A m 120 150 mm S Gear Case Service e Use high quality gear lubricant grease e Check grease level every 50 hours of operation If no grease can be seen on the inside of the filler plug fill the gear case A with grease until grease comes out of the pinion gear shaft About 8 to 10 grams full case of grease for KBL23A KBLI26A and 13 to 17 grams full case of grease for KBLI33A KBLI34A KBLI43A KBL 48A are necessary B Grease Tube www mymowertrparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 POWER TRAIN 2 17 Cutting Head Australian Model Drive Shaft Service Bearing Bush before Assembly The drive shaft is supported in 5 bearing pushes inside the guard tube It is impossible to replace the bearing bushes i e the complete guard tube has to be replaced in case of bearing damage e Inspect film of lubricant every 50 hours of operation If film of lubricant on the drive shaft is broken in places coat the areas concerned with grease
26. Before Servicing 15 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film During assembly oil or grease whichever is more suitable should be applied to any rubbing surface which has lost its lubricative film Old grease and dirty oil should be cleaned off Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles Don t use just any oil or grease Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended This manual makes reference to molybdenum disulfide grease MoS2 in the assembly of certain engine and chassis parts Always check manufacturer recommendations before using such special lubricants 16 Replacement Parts When there is a replacement instruction replace these parts with new ones every time they are removed These replacement parts will be damaged or lose their original function once removed 17 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure 18 Specifications Specification terms are defined as follows Standards show dimensions or performances
27. Change fuel Clean Clean Clean or replace eCheck and repair eCheck and repair Faulty fuel system Clogged fuel line Foul air cleaner Fuel in tank used up Clean Clean or replace Replenish Faulty carburetor www mymowerparts com Dust clogging in fuel passage Clean 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 SUPPLEMENT 5 1 SUPPLEMENT Table of Contents Rotary Valve Diaphragm Type Carburetor KBL23A KBLI2Z6A KBLIS4A ee eeeeeseeeceeeneeeeeeeeeeaeeeaeseeeeeaeenaeteaeeeaeenaeeeaees 5 2 SA aseedscresdecicetssapahceabesnsetdesacenasdagucenscensezeacd ands isds dons dsesanepebensestsraaunedsteeaseaicerssttandeses 5 2 Fuel Pump SMA Milian tea T E 5 3 Metering Chamber System secsie tccuciecficsecetee nee aaie liada 5 3 Disassembly e222 stitch Geeeeee ean ea NL ed ea A RL A id 5 4 Realice a cada 5 4 Inspection and AdjUStMOENK iii edete canvas E A dies oraa e EE ra aaaea A A 5 5 Idle Needle Pin Adjustment siira iinei aaeeea raaa nannaa e peter 5 6 Rotary Valve Diaphragm Type Carburetor Troubleshooting KBL23A KBLI26A KBLIQ4A coocccoccccccocccococccconcconncncnnccninnos 5 7 Piston Valve Diaphragm Type Carburetor KBLI33A KBLI43A KBLI48A eee eeceeeceeneeeneeenee
28. For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 KBL23A 26A a KBL33A 34A 43A 48A Kawasaki 8H26A 33A 34A 43A 48A Trimmer Brushcutter Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Department Consumer Products amp Machinery Group 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 Kawasaki Heavy Industries Ltd 1997 1999 Second Edition 1 May 31 1999 K www mymowertrparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LIST OF ABBREVIATIONS A ampere s ABDC after bottom dead center AC alternating current ATDC after top dead center BBDC before bottom dead center BDC bottom
29. about 150 to 200 mm 5 90 to 7 87 in long e www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 POWER TRAIN 2 15 Cutting Head Australian Model e Feed ends of the line A through eyelets B on the case C e Align the notches of the spool A with the eyelets B of the case to insert the spool onto the case core C e Pull both ends of the line D to complete the spool installation e Set the latch of the return spring into the notch A of the slider B as shown e Insert another latch of the return spring into the notch of the spool marked with A A to such a depth as to enable to turn the slider e Holding the slider A to align the latch of the return spring with A marked on the spool push the slider A into the case e Twist it within about 30 degrees of angle to get both top and bottom latches of the return spring settled in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 16 POWER TRAIN Cutting Head Australian Model e After the slider A was pushed onto the case core take the slider A in and out to check that it can move free e While pushing this slider onto the case insert the retainer A into the case e While holding the retainer press the case which has been set onto the cutting tool shaft attached to the equipment Operation Check e
30. and periodic maintenance this manual does not mention them as you can depend upon their respective owner s manuals and parts catalogues to tell you the details In order to perform the work efficiently and to avoid costly mistakes read the text thoroughly familiarize yourself with the procedures before stating work and then do the work carefully 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 adversely affect safe operation To get the longest life out of your equipement e Follow the Periodic Maintenance Chart in their respec tive owner s manuals e Be alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki engine parts Genuide parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual carefully Don t take shortcuts e Remember to keep complete records of maintenance and repair with dates and any new parts installed How to Use This Manual Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices This warning symbol identifies special instruc tions or procedures which if not correctly fol lowed could result in personal injury or loss of life CAUTION This caution symbol identifies
31. as KBL23A KBIJ26A shown e Remove the key D from the crankshaft e Unscrew the flange bolts E to remove the cylinder F and the cylinder gasket G from the crankcase e Scrape the carbon deposits inside the cylinder with a suitable tool O Use a scraper that are mode of a material that will not cause damage KB_143A KBLi48A www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE 3 7 Flywheel and Cylinder e Check to see if the pulse hole A under the inlet port B is clogged x If clogged clean Installation The cylinder gasket has the notches allowing crankcase pulses to pass through The cylinder gasket should be properly set according the following e Installation is the reverse of removal e Use a new gasket e Set the cylinder gasket with its direction as shown e Evenly tighten the cylinder to the crankcase with tightening torque and order specified see Tightening Torque ee e KBID33A Narrower Side Carburetor side Cylinder gasket KBO43A KBO48A Notch for pulse passage Cylinder gasket Tightening 6 gt order E ENA Cylinder gasket www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 8 ENGINE Piston and Piston Ring Removal KBO33A CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall
32. be forced out of the gear case www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 POWER TRAIN 2 11 Cutting Blade Cutting Blade Installation KBL23A KBLI26A This steel cutting blade mounting nut D is left handed thread Be careful not to injure your hands with the steel cutter blade e Turn the brushcutter upside down on the ground with its cutting tool shaft E upward e Put the holder A the steel cutting blade B and the holder C over the cutting tool shaft E O Take care that the steel cutting blade B is centered by putting it correctly on the socket and spigot joint O Put the steel cutting blade B with its arrow side marked upward on the upper holder C and center the lower holder G on the cutting blade B O Make sure the steel cutting blade B is correctly centered with the socket and the spigot joint between upper and lower holders C G e Aligning the hole of the holder C with the hole F on the gear case insert a wrench provided into the gear case through both holes to keep the shaft from turning e Tighten down the nut D to the specified torque by turning it counterclockwise Specified Torque KBL23A KBLI26A 13 15 N m 1 3 1 5 kg m KBL33A KBL134A KBL 43A KBL48A KBO33A KB034A KB043A KBO48A 15 19 N m 1 5 1 9 kg m WWwwWw mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606
33. ck valve in particular and make sure that they are flat and not bent x If they are bent replace them with no ones e Check the main diaphragm to see if there is any peeling damage or the aluminum plate bent x If they are bent replace with new one After cleaning the pump body check to see that the control lever functions well and that no dirt is found on the inlet screen CAUTION To prevent deformation or sticking of the main check valve never apply high pressure air to the valve e Check to see that there is no deformation or damage on the check 1 4 1 6mm valve Pump body surface x If any replace it with new one e Check to see that no hole damage or abnormal hardening is present on the priming pump y A ZA If present replace it with new one AOE EE e Push the tip end of the control lever lightly and make sure that the N lever moves smoothly Oe x If the needle valve which opens and closes with movement of the 2 control lever 1 has got some damage on its tip end or wear due to its long use applying air to the tip end of the needle valve 3 will not O be solution for overflow In this case replace the pump body assembly with new one e Adjust the control lever 1 so as to be at the same level as the bottom of the metering chamber as shown Xx If correction is necessary ben the lever lightly to be on the same surface of the metering chamber bottom or adjust the lever to be from 1 4 m
34. dead center BTDC before top dead center C degree s Celcius DC direct current F farad s F degree s Fahrenheit ft foot feet g gram s h hour s L liter s lb m min N Pa PS psi di rpm TDC TIR pound s meter s minute s newton s pascal s horsepower pound s per square inch revolution revolution s per minute top dead center total indicator reading volt s watt s ohm s Read OWNER S MANUAL before operating www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated exhaust emission control systems EM in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board 1 Exhaust Emission Control System The exhaust emission control system applied to this engine consists of a carburetor and an ignition system having optimum ignition timing characteristics The carburetor has been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED Federal law and California State law prohibits the following acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of an
35. eaeetneeeaeeeeeeeneeseeeeeesneeteees 5 10 DIS ASS aA olh Le tened etunerees 5 10 Reassembly it AA td Set a 5 11 Metering Chamber AdjUStMent ceeceeseeeseeeneeeeeeeseeeseeeaeeeaeeeaeseaeseaeeeaeseaeseaeeeaeseaeeeseesaeseaeeeaeesaeseaeesesseesneesneeeneenaes 5 11 Main Adjust ScrewsAdjUStm mnt sczesacecc aie etches reg Bi edecnt ches cet angie lada 5 12 Lowest Throttle Valve AdjuStMenNt o oc ia cia 5 12 Priming PUMP Syst m smc ie lan oe Pecos ees 5 13 Choke Syste Mi nania ir doraa a adas 5 14 Idling Syste Mii A A ean Naw Ben A ANER a ie 5 14 Fuel and Air Flow between Idling and Full Throttle o oonnnnninnnnonnnnnnnonncnnnonnccnrannccnnrcnrn narrar rr 5 15 Fuel and Air Flow at Full Throttle siars pei diia 5 15 Piston Valve Diaphragm Type Carburetor Troubleshooting KBLI33A KBLI43A KBLI48A coococcocccconccocnconnconncnnncnnncnnnos 5 16 Spark Arrester KBL23A KBLI26A KBLIS4A for US OMlY coooococonocccononocanonnnoncnnncnoncnnnnnnnnn nn cnn cnn rnn cnn n rn nn cnn ran 5 18 ROM liinda a eed E AO Ei 5 18 Sl ic id ii 5 18 A been cates iih eve ceed dua cabana eh Sea nachos ach a tah eta acted Meese bast ova iekedsesag daa E sas tant A 5 18 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 2 SUPPLEMENT Rotary Valve Diaphragm Type Carburetor KBL23A KB 126A KB 134A Priming Pump System When starting the engine by pushing the priming pump 18 air is pushed out toward the overflow
36. ecified speed See Setting Table www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 SUPPLEMENT 5 7 Rotary Valve Diaphragm Type Carburetor Troubleshooting KBL23A KBLI26A KBLI34A Symptom Cause Remedy Engine hard to start Idle needle pin maladustement Adjust Idle adjust screw maladjustment eAdjust Foul fuel filter in fuel tank Clean Clogging in fuel passage Clean Air leakage in fuel passage Repair Improper fuel Change Inferior check valve Replace Clogged air cleaner element Clean or replace Damaged carburetor control metering lever Repair Malfunction of carburetor control metering lever Repair Inferior main diaphragm gasket Replace Poor tightening of main diaphragm cover screw Tighten Damaged main diaphragm Replace Adherence of inlet needle valve Replace Inlet needle valve wear Replace Inlet needle valve sticking Repair Overflow fuel leakage Poor tightening of fuel pump cover screw Tighten Damaged carburetor control metering lever Repair Too high carburetor control metering lever Adjust Malfunction of carburetor control metering lever Repair Deformed carburetor control metering level spring Replace Inferior main diaphragm gasket Replace Poor tightening of main diaphragm cover screw Tighten Damaged main diaphragm Replace Inlet needle valve wear Replace Inlet needle valve sticking Repair Primin
37. er than that igniter more rapidly disconnected at begins to work connector Spark appears when Faulty ignition Wiring of coil coming short Replace ignition coil is replaced coil circuited or disconnected with new one Stop lead wire is jammed Correct or replace Spark appears when Faulty flywheel Flywheel damagnetized Replace flywheel is replaced with new one Engine Malfunction at Low Speed Symptom Cause Remedy When throttle value is opened Faulty carburetor Clogging in carburetor inside Disassemble and clean garadually revolution speed Faulty fuel filter Foul fuel filter Clean or replace drops at some position or Air enters at Faulty carburetor gasket Replace engine stops carburetor flange Incomplete fitting of carburetor Tighten When spark test of spark plug Faulty ignition Faulty insulation of spark plug Replace is made with recoil starter rope system Foul electrodes Clean pulled spark appears very Faulty magneto flywheel igni Replace week tion coil and related parts Engine Malfunction at High Speed Symptom Cause Remedy Same as Engine Malfunction Faulty carburetor Same as Engine Malfunction Same as Engine at Low Speed mentioned Faulty fuel filter at Low Speed Malfunction at Low above Faulty ignition system Loaded operation causes Clogged fuel tank cap air vent Clean revolution fluctuation with big Dust clogging in or entry of ai
38. examine what may be causing the problem Whenever tapping is necessary tap lightly using a rubber wooden or plastic faced mallet Use an impact driver for screws particularly for the removal of screws held by a locking agent in order to avoid damaging the heads 5 Edges Watch for sharp edges especially during major engine disassembly and assembly Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over 6 High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent commonly available in North America is Standard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent 7 Gasket O Ring Do not reuse a gasket or O ring once it has been in service The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks 8 Liquid Gasket Non Permanent Locking Agent Follow manufacturer s directions for cleaning and preparing surfaces where these compounds will be used Apply sparingly Excessive amounts may block engine oil passages and cause serious damage An example of a non permanent locking agent commonly available in North America is Loctite Lock n Seal Blue 9 Press A part installed using a press or driver such as a journal should first be coated with oil on its outer or inner circumference so that it will go into place smoo
39. eyvvs duke R a AREA 3 9 Crankcase and Crankshaft KBLISBA KBLIIS4A ccccccccccccssssssscceeeeceeceecceseessuaeeceeeeeeesceeesseaaeeeaeeceeeceseesnssaeeeeaseeeeeense 3 10 FRROMOVAl iced civacs caves Codeaneet cp cvateaeves oveuvees A R A AT NSE 3 10 INSTANT A ta Lantana 3 10 Crankcase and Crankshaft KBL23A KBLI26A KBLISSA KBLIQGA cccccsessscccececeeeecceeeessssaeeeeeecceeccsneessssseeeeaeeeeesenss 3 11 Crankshaft Shim Selection cccccccccccccccssssssssceeeeceeecesecesssauceeeeeeeeesseeecsesaaeeeaeeecececenesseauaeseaeseseceeesessnacenseeeeeeeesens 3 11 Crankcase and Crankshaft KBLI43A KBLI48A cc ccccccccccssssssccceeeeeeccececsnessnaeeceeeeeeesceeennsaueeeeecesecccseesessseeeeeseceeeenss 3 12 Grankshatt SHIM SeleCtiOn ss cutis 3 12 Grankcase anid CMS Mi rd eA 3 13 Crankshaft Shim Nial e a a a a a a a aa aa r ana iyi e antata 3 13 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 2 ENGINE Clutch and Fuel Tank Removal e Keeping the clutch shoes A from turning by using a pair of pliers release the clutch pins B by turning counterclockwise to remove the clutch shoes A and the clutch assembly O Take care not to scratch the clutch shoes A O Do not remove the clutch spring C if not needed e Remove the stand D e Remove the tank grommet E out of the fuel tank F e Loosen the fuel tube clamps to remove the fuel tank F together Installat
40. f A and B at the outer race not to allow ball bearing axial play to affect the shim selection D A B C KBL23A KBLI26A 0 2 0 007 1 92025 2125 0 4 0 015 92025 2126 0 6 0 023 3 92025 2127 Clearance dimension D mm Shim 0 05 0 27 without shim 0 68 0 79 3 KBL33A Shim thickness mm in Shim Part No 0 1 0 003 1 92025 2103 0 2 0 007 2 92025 2104 0 4 0 015 3 92025 2105 0 6 0 023 4 92025 2106 Shim Clearance demension D mm 0 11 0 03 0 04 0 13 0 14 0 23 3 0 24 0 33 3 0 34 0 43 4 0 44 0 53 3 3 0 54 0 63 1 2 4 KBLI34A Shim thickness mm in Shim Part No 0 2 0 007 92025 2104 0 4 0 015 92025 2105 0 6 0 023 92025 2106 Clearance dimension D mm Shim 0 05 0 27 without shim 0 28 0 47 1 0 48 0 67 2 0 68 0 79 3 Magneto side www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 12 ENGINE Crankcase and Crankshaft KBLI43A KBLI48A Whenever any one of the crankshaft the crankcase and the ball bearing is replaced select the crankshaft shim s to adjust crankshaft axial play according to crankshaft shim selection Crankshaft Shim Selection Measure dimension of A B and C shown in the figure and calculate crankshaft clearance dimension D by the following equati
41. g Clamp Screw M6 8 10 0 8 1 0 6 0 7 4 Clutch Housing MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb Cutter Blade Mounting Nut M10 15 19 1 5 1 9 11 14 Tightening Torque KBLI43A KBLI48A Fasteners Size Nem oe tib Remarks Air Cleaner Cap MTGS M4 1 7 2 0 0 17 0 20 15 18 in lb Air Cleaner Case MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb Ignition Coil MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb Recoil Starter MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb LA Engine Shroud MTGS M4 1 7 2 0 0 17 0 20 15 18 in lb LA 3 5 4 0 0 35 0 40 31 35 in lb Muffler MTGS M6 7 0 8 0 0 70 0 80 62 71 in lb M5 3 5 4 0 0 35 0 40 31 35 in lb 7 0 9 0 0 70 0 90 62 80 inb Clutch Shoe MTGS M8 14 16 1 40 1 60 10 12 LA 14 16 1 40 1 60 10 12 10 12 1 00 1 20 89 106 in lb Spark Plug M14 12 17 1 20 1 70 8 9 13 Gear Case Clamp Screw M6 8 0 10 0 0 80 1 00 71 89 in lb Gear Case Alignment Screw M5 3 5 4 0 0 35 0 40 31 35 in lb Grease Hole Bolt M6 4 0 5 0 0 40 0 50 35 44 in lb Clutch Housing Alignment Screw M5 3 5 4 0 0 35 0 40 31 35 in lb Clutch Housing Clamp Screw M6 8 0 10 0 80 1 00 71 89 in lb Clutch Housing MTGS M6 8 0 10 0 80 1 00 71 89 in lb Cutting Tool Guard MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 11 Clearance Table Clearance Table Unit mm in Service
42. g is hard to suck fuel Clogged fuel tank cap air vent Clean Foul fuel filter in fuel tank Clean Clogged fuel line Clean Air leakage in fuel line Repair Damaged priming pump Replace Inferior priming pump check valve Replace Malfunction of carburetor control metering lever Repair Inferior main diaphragm gasket Replace Poor Tightening of main diaphragm cover screw Tighten Damaged main diaphragm Replace Adherence of inlet needle valve Replace Engine would not idle eldle needle pin maladjustment Adjust Idle adjust screw maladjustment Adjust Foul fuel filter in fuel tank Clean Air leakage in fuel line Repair Interior manifold O ring Replace Poor tightening of carburetor Tighten www mymowertrparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 8 SUPPLEMENT Rotary Valve Diaphragm Type Carburetor Troubleshooting KBL23A KB 126A KB 134A Symptom Cause Remedy Idling is too slow Idle needle pin maladjustment Adjust Clogged air cleaner element Clean or replace Damaged carburetor control metering lever Replace Carburetor control metering lever is too high Adjust Malfunction of carburetor control metering lever Replace Inlet needle valve wear Replace Forein matter sicking Clean Idling is unstable Idle needle pin maladjustment Adjust Idle adjust screw maladjustment Adjust Clogged fuel tank cap air vent Clean Foul fuel ta
43. gs Replace Hunting Symptom Cause Remedy Hunting Foul air cleaner Clean Dust clogging in or air entry into fuel pipe Clean Clogged fuel tank cap air vent Clean Clogged carburetor Clean Fuel Leakage from Carburetor Fuel leak from carburetor Foreign matter attached to needle valve and or Clean valve seat Clean Correction or wear in needle valve and or valve seat Replace needle valve assembly Poor tightening of diaphragm gasket Tighten or replace Excessive Fuel Consumption Symptom Same as Hard Starting Sufficient compression but Remedy Same as Hard Starting Adjust Poor compression Too rich fuel mixture Same as Hard Starting excessive fuel consumption Inferior fuel Replace Foul air cleaner Clean Too high idling speed Adjust Choke valve not fully open Adjust www mymowertrparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING 4 5 Engine Troubleshooting Engine Stops during Operation Symptom Cause Remedy Difficulty in cranking or Overheat seizure Cranking is easy Faulty electrical system Excessively lean fuel mixture too little fuel Inferior lubricating oil mixed Excessive carbon deposit in conbustion chamber Dust accumulation on cooling fins of cylinder Faulty spark plug Faulty magneto eLoseness in connections eAdjust carburetor
44. he connecting rod and the needle bearing are inseparable This means that the crankshaft must always be replaced as a complete unit in the vent of damage to any one of these parts when fitting a replacement always install new ball bearings The complete crankcase must be replaced if either half is damaged e Installation is the reverse of removal O Apply fine oil to both ball bearings O Apply heat resisting grease between oil seal lips e f the original crankcase is reused remove the gasket stuck and clean the sealing surfaces They must be cleaned thoroughly to ensure a perfect seal e Put the new gasket on the sealing surface of the crankcase so that the dwel pins are in position or fit them in the new gasket and tighten the bolts to the specified torque evenly in the order shown See Tightening Torque e Carefully cutaway any crankcase gasket that is proud of the cylinder flange surface www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE 3 11 Crankcase and Crankshaft KBL23A KBL126A KBL133A KBL134A Whenever any one of the crankshaft the crankcase and the ball bearing is replace select the crankshaft shim s to adjust crankshaft axial play according to crankshaft shim selection Crankshaft Shim Selection Measure dimension of A B and C shown in the figure and calculate crankshaft clearance dimension D by the following equation Important Measure dimension o
45. ing and the guard tube so that it can keep the guard tube from turning and coming off Thus it is almost impossible to remove not only the ball bearings but the clutch drum e Unscrew the mounting screw A to remove the carburetor cover B e Remove the cable end nipple A out of the throttle valve terminal B e Release the cable adjuster locknut C to remove the cable adjuster D out of the bracket E e Release the guard tube clamp screw A and the lead wire connectors B C e Pull the complete engine out of the guard tube A and withdraw the drive shaft B www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 POWER TRAIN 2 3 Complete Engine Complete Engine Removal KBLI33A KBL34A KBU43A KBLI48A It is very hard to remove the combination damper out of the clutch housing in order for friction to make the engine kept from turning relatively to the guard tube being almost impossible to remove also the clutch drum e Snap the joint case A open e Detouch the cable end nipple B out of the cable end stub C e Release the locknut D to remove the mid adjuster E out of the joint case A together with the throttle cable F e Remove the set screw A keeping the engine from turning e Release the guard tube clamp screw B just enough to withdraw the complete engine out of the guard tube e Unfasten the stop switch lead connectors A B and untie the clamp C
46. ing rod and the needle bearing are inseparable This means that the crankshaft must always be replaced as a complete unit in the event of damage to any one of these parts when fitting a replacement always install new ball bearings The complete crankcase must be replaced if either half is damaged e Installation is the reverse of removal O Apply fine oil to both ball bearings O Apply heat resisting grease between oil seal lips e f the original crankcase if reused remove liquid must be cleaned thoroughly to ensure a perfect seal e Sparingly apply liquid gasket on the sealing surface of the starter half of the crankcase CAUTION Excessive amounts may block something inside and cause serious damage e Put the flywheel half of the crankcase onto the starter half of the crankcase so that the dowel pins can be fit into their holes of the flywheel half of the crankcase and tighten the bolts to the specified torque evenly in the order shown see Tightening Torque www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 10 ENGINE Crankcase and Crankshaft KBLI33A KBLI34A Removal KBO33A e Unscrew the tightening screws to split the crankcase 2 from the crankcase 1 O Lightly tap the crankcase with a plastic hammer to split it O Take care not to damage the oil seals O Take care not to lose the adjusting shims 0 to 3 pieces Crankshaft Installation The crankshaft t
47. ion e Installation is the reverse of removal NOTE Apply a bit of 2 stroke engine oil to the grommet in order to make the insertion easy e Fix the fuel filter to the delivery side opaque tube and clamp it e Install the tank grommet to the fuel tank so that the transparent tube comes toward the fuel tank center e Put the opaque tube into the fuel tank together with the fuel filter and fit the tank grommet into its hole in order that the raised letters on the tank grommet can look toward outside e Apply locking agent to screw threads of the clutch pins B e Apply a bit of heat resisting grease to the clutch pin holes e Put the clutch shoes A and the plate G on the flywheel with raised letter s such as R54 for KBII26A R78 for KBLI43A KBL148A and R for KBO33A KBO34A toward you to install them by tightening the clutch pins B to the specified torque Specified Clutch Pin Tightening Torque KBL23A KBL126A 8 10 N m 0 8 1 0 kg m KBO33A KBO34A KB043A KB048A 14 16 N m 1 4 1 6 kg m e Install the clutch spring C to the clutch shoes A before installing the clutch shoes A on the flywheel if the clutch spring is removed KBL23A KB 43A KB 48A www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE 3 3 Air Cleaner carburetor and Muffler
48. ir Pulse leakage from fuel pump Repair Clogged pulse passage Clean Poor tigtening of pump cover screw Tighten Inferior of pump diaphragm Replace Inferior of check valve Repair Inferior of manifold O ring Replace Poor tigtening of carburetor Tighten Damaged carburetor control metering lever Replace Too low carburetor control meterian lever Adjust Malfunction of carburetor control metering lever Replace Poor installation of carburetor control metering lever Correct Damaged carburetor control metering lever button Replace Poor tightening of diaphragm cover Tighten Damaged diaphragm Replace Adherence of inlet needle valve Replace Engine stops when decelrating Idle needle pin maladjustment Adjust Interior pump diaphragm Replace Too high carburetor control metering lever Adjust Malfunction of carburetor control metering lever Replace Inlet needle valve wear Replace Foreign matter stticking of inlet needle Clean Engine does not accelerate Idle needle pin maladjustment Adjust quick Clogged air cleaner element Clean Malfunction at high speed Clogged fuel tank cap air vent Clean Four fuel tank filter Clean Clogged fuel line Clean Air leakage in fuel line Repair Improper fuel Change Pulse leakage from pulse pump Repair Poor tightening of pump cover screw Tighten Inferior of pump diaphragm Replace Inferior of check valve Replace Clogged air cleaner e
49. le WO IN valve REY Cred ER NN AN Needle jet y D www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 SUPPLEMENT 5 15 Piston Valve Diaphragm Type Carburetor KBLI33A KBL143A KBLi48A Fuel and Air Flow between Idling and Full Throttle When increasing the throttle valve opening clearance between the needle jet and the jet needle increases gradually and fuel flow rate from the jet and the jet needle increases gradually and fuel flow rate from the jet also increases Fuel flow rate is controlled by the clearance By this movement of the throttle valve at the same time intake air amount passing through the carburetor also increases and air fuel mixture to meet requirement of the engine from idling to high speed running can be supplied Fuel and Air Flow at Full Throttle At this time the throttle valve is positioned at the highest in the carburetor and opening of the valve becomes maximum full Fuel flow rate is controlled largely by the main jet and opening of the jet is adjusted by the main adjust screw Throttle valve Main jet Main adjust screw www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 16 SUPPLEMENT Piston Valve Diaphragm Type Carburetor Troubleshooting KBL33A KBLI43A KBLi48A Condition Probable cause Remedy Hard No fuel drain into Clogging in fuel tube at inlet Remove and clean the tube
50. lean the check valve portion Adjust the control lever height properly Retighten the fitting bolts or replace the fitting gasket eAdjust the opening of throttle valve at idling with throttle stop screw Disassemble and clean the check valve portion Disassemble and clean Insert the clip to the proper position 2nd stage of jet needle Change the clip to upper position of jet needle If not good replace the jet needle and the carburetor body Adjust the control lever height properly www mymowertrparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 18 SUPPLEMENT Spark Arrester KBL23A KBL126A KB034A for US only KBL23A KBO26A KBO34A for US only are equipped with a muffler in which a spark arrester is installed Clean the net of the spark arrester every 50 hours of operation according to the following manner Removal Do not attempt to service a hot exhaust muffler or severe burns could result Always allow the exhaust muffler to cool prior to service e Unscrew a muffler cover mounting screw A to remove the plastic muffler cover B together with a guard C CAUTION Do not remove the guard C unless it is necessary as a tapping screw K has gnawed at the plastic muffler cover B e Unscrew the muffler mounting screws D to remove the muffler assembly M out of the engine together with a gasket E e Unscrew a tapping screw
51. lement Clean Inferior of manifold O ring Replace Poor tightening of carburetor screw Tighten Damaged carburetor control metering lever Replace Malfunction of carburetor control metering lever Replace Deformation of carburetor control metering lever Replace Poor installation of control lever spring Correct Damaged main diaphragm button Replace Inferior of main diaphragm gasket Replace Poor tightening of main diaphragm cover Tighten Damaged main diaphragm Replace Inlet needle valve wear Replace Foreign matter sticking of inlet needle Clean www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 10 SUPPLEMENT Piston Valve Diaphragm Type Carburetor KBLI33A KBLI43A KBLi48A Disassembly Before disassembling clean the carburetor with cleaning oil so that no dirt enters the carburetor e Unscrew to remove the plate 38 and the priming pump 37 e Remove the pump cover 35 the gasket 34 the pump plate 33 the pump diaphragm 30 and the gaskets 29 31 32 O Check to see if the gaskets 29 31 32 34 and the pump diaphragm 30 are not damaged and confirm outflow of air from the other side of the passage e Unscrew to remove the control lever 17 the control lever pin 18 the control lever spring 16 and the needle valve 15 e Unscrew to remove the plate 22 the check valve 21 and the gasket 20 e Remove the cap 1 and
52. m 0 055 in to 1 6 mm 0 062 in with surface of the pump body as standard e To check function of the main check valve stick vinyl pipe end to the main check valve and breathe in and out from the other end x If the valve opens when breathing in and closes when breathing out the valve functions well e f any problems are found soak the valve in gasoline for about 10 minutes and repeat breathing in and out several times x If no improvement shows replace the pump body 2 with new one www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 6 SUPPLEMENT Rotary Valve Diaphragm Type Carburetor KBL23A KB 126A KB 134A Idle Needle Pin Adjustment e Start the engine and move the throttle lever to its fully closed position Raise the engine speed just before the cutting tool begins turning by turning the idle adjust screw clockwise e Adjust the idle needle pin where the engine speed rises highest by turning it clockwise or counter clockwise When the engine speed rises and the cutting tool begins turning lower the engine speed by turning the idle adjust screw counterclockwise and readjust the idle needle pin where the engine speed rises highest right before the cutting tool begins turning by turning the pin clockwise or counterclockwise e When the idle needle pin position is fixed turn the idle needle pin 1 4 to 1 2 turn more and stop turning e And then adjust the idle adjust screw to the sp
53. mation of tip of the screw and screw seat on the body and results in malfunction of the carburetor Lowest Throttle Valve Adjustment e Adjust the lowest position of the throttle valve by turning the screw so that opening of the throttle valve may reach about 1 mm 0 04 in About 1mm www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 SUPPLEMENT 5 13 Piston Valve Diaphragm Type Carburetor KBLI33A KBL143A KBLi48A Priming Pump System When starting the engine by pushing the priming pump 12 several times by hand pressure in metering chamber lowers and the main diaphragm 9 the needle valve 8 is opened and fuel flows into metering chamber 21 Overflow from the chamber flows back into the fuel tank through the fuel outlet 14 Pushing should be stopped as soon as overflow appears out of the fuel outlet 14 During operation of the priming pump 12 the main check valve 15 is closed by negative pressure to check air suction from the needle jet 18 into the metering chamber 21 Needle Jet Throttle Stop Screw Fuel Inlet 18 Pump Diaphragm 19 Suction Check Valve 20 Delivery Check Valve 21 Check Valve Spring 22 Pump Chamber 23 Pulse Chamber Needle Valve Main Adjust Screw Metering Chamber Cable Adjuster Rubber Cap 00D O O a Y ND Main Diaphragm _ e Control Lever mb cb Control Lever Spring N
54. minate unnecessary work Photographs diagrams notes cautions warnings and detailed descriptions have been included 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 the engine For the same reason before installing a new part clean off any dust or metal filings 2 Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them evenly in a staggered sequence This is to avoid distortion of the part and or causing gas or oil leakage Conversely when loosening the bolts nuts or screws first loosen all of them by about a quarter of a turn and then remove them Where there is a tightening sequence indication in this Service Manual the bolts nuts or screws must be tightened in the order and method indicated 3 Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench 4 Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or install stop and
55. mowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 2 TROUBLESHOOTING Engine Troubleshooting Hard Starting Symptom Cause Remedy Pulling recoil starter handle Poor compression Wear in piston Replace would not cause sufficient Wear in piston ring Replace compression Stick of piston ring Wear or deformation of clinder boce Poor tightening of cylinder and spark plug Clean ring groove and replace piston ring Replace cylinder and piston ring as a set Tighten After choking and making several starting attempts it is found on removing spark plug that electrodes are still dry Insufficient fuel No fuel in fuel tank Clogging of dust or entry of air in fuel pipe Clogged fuel tank cap air vent Foul fuel filter in fuel tank Poor opening and closing of choke valve Air entering at gasket fitted to carburetor flange Clogged carburetor needle jet or main jet Replenish Clean Clean Clean Correct Tighten or replace gasket Clean After choking and making Excess fuel Faulty choking In summer or Remove spark plug with several starting attempts it is when engine is warm full engine switch OFF on removing spark choking gives too rich mix exhaust excess fuel by plug that electrodes are ture pulling starter rope excessively wet Overflow of fuel from Check carburetor and carburetor exhaust excess fuel from cylinder Clogged
56. nk fuel filter Clean Clogged fuel line Clean Air leakage in fuel line Repair Improper fuel Change Inferior check valve foreign matter Replace Inferior manifold O ring Replace Poor tightening of carburetor Tighten Malfunction of carburetor control metering lever Replace Poor installation of carburetor control lever Correct Damaged main diaphragm Replace Adherence of inlet needle valve Replace Foreign matter sticking Clean Idling does not continue eldling needle pin maladjustment Adjust eldling adjust screw maladjustment Adjust Foul fuel tank filter Clean Clogged fuel line Clean Air leakage in fuel line Repair Inferior check valve foreign matter Replace Too high carburetor control metering lever Adjust Malfuncion of carburetor control metering lever Replace Deformation of carburetor control metering lever Replace Poor installation of carburetor control lever spring Correct Inlet needle valve wear Replace Foreign matter sicking of inlet needle Clean www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 SUPPLEMENT 5 9 Rotary Valve Diaphragm Type Carburetor Troubleshooting KBL23A KBLI26A KBLI34A Symptom Cause Remedy Engine does not accelerate Idle needle pin maladjustment Adjust Clogged fuel tank cap air vent Clean Foul fuel tank filter Clean Clogged fuel line Clean Air leakage in fuel line Repa
57. ntrifugal type mm in 454 2 1 Fuel Mixing ratio Regular unleaded gasoline 50 1 2 stroke engine oil Tank capacity litre 0 5 06 e 0 6 Drive shaft Cutter Nylon string asembly amp gear Dia of string mm in 42 4 0 095 housing Bearing of shaft 5 plane Rotation Counterclockwise Lubrication High quality lithium grease Drive shaft dia mm in p6 0 24 Drive shaft metarial High tensile steel Reduction ratio 14 19 Guard Plastic guard on the pipe assembly Weight The unit without cutting attachment and shoulder harness empty fuel tank www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 1 6 GENERAL INFORMATION General Specifications Model KBH33A KBL33A KBH34A KBL34A Handle type Double Loop Double Loop handles handle handles handle Engine Type Forced air cooled 2 stroke horizontal shaft gasoline engine Displacement 33 3 33 3 33 3 33 3 ml cu in 2 03 2 03 2 03 2 03 Carburetor Diaphragm type Ignition Solid state ignition Spark plug NGK BMR6A Starter Recoil starter Clutch drum dia Automatic centrifugal type mm in 9478 3 1 Fuel Mixing ratio Regular unleaded gaoline 50 1 2 stroke engine oil Tank capacity litre 0 8 0 8 0 8 0 8 Drive shaft ass y Cutter Nylon cord 8 gear housing Dia of cord mm in 42 4 0 095 Bearing of shaft 5 plane Rotation Counterclockwise Lubrication High quality li
58. on Important Measure dimension of A and B at the outer race not to allow ball bearing axial play to affect the shim selection A D A B C KBLI43A KBLI48A Shim thickness mm in Shim Part No 0 2 0 007 1 92025 2135 0 4 0 015 92025 2136 0 6 0 023 3 92025 2137 Clearance dimension D mm Shim 0 05 0 27 without shim 3 0 68 0 79 Magneto side www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE 3 13 Crankcase and Crankshaft Crankshaft Shim Installation e Install shim s selected onto the crankshaft as shown and assemble the crankcase Crankshaft Axial Play Standard 0 05 0 295 mm 0 002 0 011 in does not include that of ball bearings 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 TROUBLESHOOTING 4 1 TROUBLESHOOTING Table of Contents Engine Troubleshooting A a a NOA Engine Malfunction at Low Speed Engine Malfunction at High Speed Insufficient POWET 0 eee eeeeseseetseeeseeeeeeteeeteeeeeaeteeetseee Abnormal Engine Noises i c scccscicden cee eciee di deere HUNING geci E a N a eit ee aed ees aes ere anes Fuel Leakage from Carb retor sinisisi aa eaaa ei ds Tranas aan Excessive Fuel CONSUMO nicnn liada Engine Stops during Operation www my
59. out and score the cylinder wall e Remove snap rings F out of the piston B e Pull the piston pin C off the piston B to remove the piston B and the needle bearing D out of small end of the connecting rod E e Remove piston rings A out of the piston B Installation e Installation is the reverse of removal e Position the piston rings A in order that the radii at the ring gap can meet at the piston ring stopper pin B in the piston groove when the rings are compressed e Fit the needle bearing into small end of the connecting rod to install KBL33A the piston to small end of the connecting rod with the mark A on piston crown pointing to specified side with the piston pin KBO33A e Arrow on piston crown should point to flywheel side KBH43A e E on piston crown should face muffler side KBL23A KB026A KB034A KBH48A e H on piston crown should face muffler side www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE 3 9 Crankcase and Crankshaft KBL23A KBL126A KBL134A KBLI43A KBL148A Removal KBL23A KB 126A e Unscrew the tightening screws to split the crankcase 2 from the Crankcase r7 3 crankcase 1 e O Lightly tap the crankcase with a plastic hammer to split it O Take care not to damage the oil seals O Take care not to lose the adjusting shims 0 to 3 pieces Installation The crankshaft the connect
60. pull up the throttle wire to take out the throttle valve 9 e Remove the throttle wire from the throttle valve 9 to remove the spring 5 the retainer 6 and the jet needle 8 CAUTION Do not remove the needle clip 7 if adjusting is not necessary e Remove the throttle stop screw 10 and the main adjust screw 12 together with the springs 11 14 from the carburetor body and check to see if tip of each screw is not damaged and free from foreign material Xx If abnormal condition is found on the throttle stop screw 10 or main adjust screw 12 replace with new ones www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 SUPPLEMENT 5 11 Piston Valve Diaphragm Type Carburetor KBLI33A KBL143A KBLi48A CAUTION and so on take care not to damage seat surface to the check valve and contact area of the valve When removing the check valve do not sue tip of a screw driver a metal and the like Do not remove the check valve installed into the priming pump cover normary If it is removed because of clogging with dust Seat surface Valve contact area Pump cover e Unscrew to remove the diaphragm cover the main diaphragm and the gasket O Check to see if the main diaphragm is not ripped or does not come off and the aluminum disk of the diaphragm is not deformed If the di i i x If the diaphragm or the gasket is damaged replace with new one Aimn m diek
61. r into fuel pipe or Clean frequency carburetor www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 4 TROUBLESHOOTING Engine Troubleshooting Insufficient Power Symptom Cause Remedy Same as Hard Starting Same as Hard Starting Poor compression Insufficient fuel Excess fuel Faulty fuel Faulty magneto Faulty igniter Same as Hard Starting Engine overheated Clogged air cleaner Clean Carbon deposit inside combustion chamber Clean Inappropriate mixing ratio too little oil Change fuel Broken cooling fan blade Replace Dirt or dust attached to cooling fins of cylinder Clean frequency Grass of dirt attached to cooling air passage and Clean flywheel blade Excess fuel Faulty exhaust system Same as Hard Starting Clean Same as Hard Starting eCarbon deposit narrows exhaust passage and muffler Excessive oil mixed Thick smoke issues from exhaust port Change fuel Change fuel Engine knocking Interior fuel Abnormal Engine Noises Symptom Cause Remedy Piston Slapping Cylinder and piston ring wear Replace Wear and or deformation in piston Replace eCarbon deposit inside combustion chamger Clean Wear in piston pin and connecting rod small end Replace bearing Wear in piston and piston pin Replace Connecting rod noise Wear in large and small end bearin
62. sy Be careful with the hot gear case and relative parts They may be hot enough to burn you severely e Pull the drive pinion G off the gear case F together with the ball bearings H J and then pull the cutting tool shaft B off the gear case F together with the ball bearing K and the bevel gear L e Hit the gear case against a wooden block to get the ball bearing M falling out of the gear case F e Remove the circlip N out of the pinion G to separate the ball bearings H J from the pinion G www mymowertrparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 10 POWER TRAIN Gear Case Reassembly KBL23A KBLI26A e Reassembly is the reverse of disassembly e Adjusting clearance X as specified install the cover L on the gear case D Specified Clearance 0 2 to 1 0 mm 0 008 to 0 04 in Gear Case Lubrication Use a heavy duty grease for lubrication of the bevel bearing The grease level should be checked after first 50 hours of operation and added as necessary Thereafter check every 20 hours of operation To do this release to remove the filler plug F on the side of the gear case C If no grease can be seen inside the gear case squeeze grease into the gear case Do not squeeze grease more than 10g at a time CAUTION The gear case must not be completely filled with grease i e heat during normal operation would cause grease to
63. the test leads to the points shown and read the resistance X If the resistance is not as specified replace the ignition coil X If the meter reads as specified the ignition coil windings probably good However if the ignition system still does not perform as it should after all other components have been checked replace the ignition coil with one know to be good Ignition Coil Specified Resistance Resistance Between KB I33A B and C A and C Primary Winding Secondary Winding KBL23A KB 0 8 Q to 1 2 Q Rx1 Q 9 kQ to 15 kQ Rx1 KQ KBO33A 0 3 Q to 0 7 Q Rx1 Q 9 3 kQ to 15 6 kQ Rx1 k9 KBII34A 0 4 Q to 0 6 Q Rx1 Q KBH43A KBH48A 0 7 Q to 1 2 Q Rx1 Q 8 K to 13 k Bx1 KO 9 4 k2 to 15 6 kQ Rx1 KQ NOTE It is unable to inspect the igniter whether it is good or bad with the Kawasaki hand tester since it was integrated with the ignition coil kBr43A KBII48A Whenever you have doubt as to function of the igniter to operate try replacing the ignition coil with one known to be good www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 6 ENGINE Flywheel and Cylinder Removal KBO33A e Release the flywheel nut A counterclockwise to remove it together with the spring washer B and the plain washer C e Release the flywheel H out of the crankshaft by using a puller I
64. thium grease Drive shaft dia mm in 48 0 31 Drive shaft material High tensile steel Reduction ratio 17 21 Guard Plastic guard on the pipe ass y Weight The unit without cutting attachment and shoulder harness empty fuel tank www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 7 General Specifications Model KBH43A KBL43A KBH48A KBL48A Handle type Double Loop Double Loop handles handle handles handle Engine Type Forced air cooled 2 stroke horizontal shaft gasoline engine Displacement 43 2 43 2 48 6 48 6 ml cu in 2 64 2 64 2 97 2 97 Carburetor Diaphragm type Ignition Solid state ignition Spark plug NGK BMR6A Starter Recoil starter Clutch drum dia Automatic centrifugal type mm in 78 3 1 Fuel Mixing ratio Regular unleaded gaoline 50 1 2 stroke engine oil Tank capacity litre 1 0 1 0 1 0 1 0 Drive shaft ass y Cutter Nylon cord 8 gear housing Dia of cord mm in 42 4 0 095 Bearing of shaft 5 plane Rotation Counterclockwise Lubrication High quality lithium grease Drive shaft dia mm in 8 0 31 Drive shaft material High tensile steel Reduction ratio 17 21 Guard Plastic guard on the pipe ass y Weight The unit without cutting attachment and shoulder harness empty fuel tank www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 1
65. thly 10 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 11 Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally damages seals When pressing in a seal which has manufacturer s marks press it in with the marks facing out Seals should be pressed into place using a suitable driver which contacts evenly with the side of seal until the face of the seal is even with the end of the hole 12 Seal Guide A seal guide is require 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 preferable high temperature grease on the lips to reduce rubber to metal friction 13 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 14 Cotter Pin Replace any cotter pins that were removed with new ones as removal deforms and breaks them www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 3
66. torque KBL23A KB 26A www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 8 POWER TRAIN Gear Case Disassembly KBL23A KB_126A e Remove the circlips A B out of their respective grooves Heat the complete gear case to about 110 C to 140 C 230 F to 280 F on a heating plate to make bearing removal easy AWARNING Be careful with the hot gear case and relative parts They may be hot enough to burn you severely e Pull the drive pinion C off the gear case D together with the ball bearing E and then pull the cutting tool shaft F off the case D together with the ball bearing G and the bevel gear H e Remove the circlip K to press the drive pinion C out of the ball bearing E e Hit the gear case against a wooden block to get the ball bearing J falling out of the gear case D e Remove the circlip K out of the pinion C to separate the ball bearing E from the drive pinion C WWwwWw mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 POWER TRAIN 2 9 Gear Case Disassembly KBLI33A KBL134A KBL43A KBL48A e Remove the circlips A out of the cutting tool shaft B e Pry out the oil seal C e Remove the circlips D E out of respective grooves O Heat the complete gear case to about 110 C to 140 C 230 F to 280 F on a heating plate to make bearing removal ea
67. uretor eAdjust the screw properly Disassemble and clean Disassemble and clean needle valve portion and adjust the control lever height properly If not good replace the needle valve Open choke valve after starting Disassemble and clean the pulse passage eAdjust the control lever height properly www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 SUPPLEMENT 5 17 Piston Valve Diaphragm Type Carburetor Troubleshooting KBL33A KBLI43A KBLi48A Probable cause Remedy Condition Engine Unstable idling and malfunction the running does not at low not continue speed Engine does not accelerate in spite of opening throttle valve Air entering engine through the fitting portion of carburetor Too low idling speed rpm Clogged main check valve Clogged needle jet Improper position of clip to jet needle Worn jet needle or needle jet Improper height of control lever Clogging in fuel tube at inlet side Fuel passage or pulse passage of fuel pump is clogged Main adjust screw not adjusted properly Clogged needle jet Clogged main check valve Improper height of control lever Improper position of clip to jet needle Retighten the fitting bolts of the carburetor Adjust the idling speed with throttle stop screw Disassemble and clean the check valve portion Disassemble and clean Insert the
68. use of a non permanent locking agent or requid gasket Letters used in the following Tightening Torque table mean LA Apply a non permanent locking agent to the threads LG Apply a liquid gasket to the sealing surfaces MTGS Mounting screw s Tightening Torque KBL23A KBLI26A Fasteners Sie Navi Toe lb Remarks Air Cleaner Cap MTGS M5 20 25 0 20 0 25 18 22 in lb Ignition Coil MTGS M4 2 0 2 5 0 20 0 25 18 22 in lb LA Recoil Starter MTGS M4 1 7 2 0 0 17 0 20 15 18 in lb LA Crankcase Connecting Screw M5 3 5 4 0 0 35 0 40 31 35 in lb LA LG 3 5 4 0 0 35 0 40 31 35 in lb LA 3 5 4 0 0 35 0 40 31 35 in lb Insulator MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb LA Fuel Tank MTGS Crankcase side M5 3 5 4 0 0 35 0 40 31 35 in lb Fuel Tank MTGS Recoil Starter side M5 20 25 0 20 0 25 18 22 in lb Muffler MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb LA Muffler Cover MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb LA 3 5 4 0 0 35 0 40 31 35 inlb CA Clutch Shoe MTGS M6 8 0 10 0 80 1 00 71 89 in lb LA Flywheel Nut M6 8 0 10 0 80 1 00 71 89 in lb 14 16 1 40 1 60 10 12 10 12 1 00 1 20 7 2 8 7 Spark Plug M14 12 17 1 20 1 70 8 9 13 Gear Case Clamp Screw M5 3 5 4 0 0 35 0 40 31 35 in lb Gear Case Alignment Screw M5 3 5 4 0 0 35 0 40 31 35 in lb Grease Hole Bolt M6 4 0 5 0 0 40
69. y 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 Carburetor and internal parts Spark plugs Magnet or electronic ignition system Fuel filter Air cleaner elements 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 information to make it useful to the owner who desires to perform his own basic maintenance anbd repair work A basic knowledge of mechanics the proper use of tools and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily Whenever the owner has insufficient experience or has doubts as to his ability to do the work all adjustments maintenance and repair should be carried out only by qualified mechanics This manual covers models KBL23A KBH26A KBL26A KBH33A KBL33A KBH34A KBL34A KBH43A KBL43A KBH48A and KBL48A As for safety information specifications exploded view assembly and preparation operating instructions

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