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Service Manual

1. Governor Arm Removal e Remove Control Panel Assembly e Loosen the clamp nut A and take off the governor arm B e Unhooking the throttle link rod spring C end loop and clear the throttle link rod end D www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 6 FUEL SYSTEM Governor Link Mechanism Governor Arm Installation e Insert the jig pin 2 mm dia I through the jig pin hole of governor shaft B e Install the governor arm A onto the governor shaft B temporarily e Be sure the link spring C around the throttle link rod D is inplace and that it pulls the governor arm and throttle lever E each other e Loosen the clamp nut F on the governor arm enough to move the governor shaft e Turn the top end of the governor arm counterclockwise to fully open the carburetor G throttle valve and hold it there e Using the jig pin I turn the governor shaft counterclockwise fully turn the shaft to end of its travel e Tighten the clamp nut Torque Governor Arm Clamp Nut 7 8 N m 0 80 kgf m 69 in Ib e Be sure the governor shaft extend from the governor arm is approxi mately 6 5 mm 0 26 in H as shown e Remove the jig pin I e Install the control panel assembly and connect the governor arm with the governor spring 830P208052 C Governor Assembly Removal e Remove the crankcase cover see Camshaft Crankshaft chapter e Remove the push rod
2. 635 0 57001 1116 Piston Ring Compression Grip 57001 1095 Valve Seat Cutter 32 33 0 57001 1199 Piston Ring Compression Belt 67 079 57001 1097 Compression Gauge Adapter M14 x 1 25 57001 1159 Valve Seat Cutter Holder Bar 57001 1128 Valve Seat Cutter 32 30 57001 1120 ES www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 1 10 GENERAL INFORMATION Special Tools Oil Filter Wrench 57001 1249 Kawasaki Bond Silicone Sealant 56019 120 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 2 1 Fuel System Table of Contents Exploded View nirman tee A eee ees 2 2 SPCCHIGATIONS 255 foe A ES T E A E TE AN 2 4 Governor Link MechanisM cosa oo Ai 2 5 Control Panel Assembly Removal ivi A a Abe 2 5 Control Panel Assembly Installations isnin enara sniga eiiean aae EEEE Sa A AAAA SE AASEN EERI 2 5 Governor Arm Removals ferae nri piled eared een ded Maen E eee 2 5 GovernonArim NStallation sc do cath Sees ate peice renee AU at eee he No 2 6 Governor Assembly Removal ivi a dl 2 6 Governor Assembly Installati n siiis aeiee i i i e tado 2 6 Governor Assembly Inspection rric niee e a a a a iii 2 7 Governor Shaft Removal miii anata haven ean EAE NER E E adios 2 7 Governor Shaft INStall ation ics aa aE eaei Easa 2 7 Carburetors
3. If the muffler is damaged it should be replaced for best performance and least noise e Check the muffler for distortion and or loose internal components Loss of power could develop if the muffler loose the internal compo nents restricting the exhaust flow e Check for breaks in the seams and check weld at the junction of the exhaust pipes and muffler e Tap the muffler with a plastic hammer to decarbonize 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 5 1 Lubrication System Table of Contents Exploded Mi Wii A ANA ee 5 2 Engine Oil Flow Chart iaa iia ri n 5 3 Specifications iaiiaeeeai e a a a elena 5 4 Engine Oil Oil Filter and Oil Cooler ici cccccccvceseees sex cceseds a sensei et E Eae ETA E EET ei AA EEEE Ea 5 5 Oil Level INSPECUON eaei nunnia sayede aaa eee dt aa NEA tee ee ed ast 5 5 OMAN ii A eA ee ee eet eet 5 5 GiliRilter Removal Jato lisis metidos deco fon dieta ER ados Roads Wie R ani e neos foe Fess teh UDI Be tbe eG it oh Basie at 5 6 Ol Filter Installation a ad e E a e te le 5 6 Oil Cooler RemovaleFH 72D iii A E 5 6 Gil Gooler Installation H721D 0002000 ii a rt 5 6 Oil Cooler Cleaning FH721 Dy iii ba daa aid cab 5 7 Pressurized L brication Sy Mc aae iaaa aa A aa aaaea cased Aa a h ss AR E EAEE aaia 5 8 Oil Pressure Messur Met Aaa aaa ara a nadar
4. away as possible from replaced NO gt lIncorrect air gap Correct Faulty flywheel Replace Make starting attempts H NO No fuel in the tank Add Is compression sufficient ne a number of times and then remove spark plug and observe electrodes Are they wet NO7 Entry of dust or air into fuel pipe or filter Plugged air hole in tank cap and fuel pump Plugged fuel line Clean Clean Clean YES gt Excessive use of choke Remove the plug and turn the crankshaft without loading Plugged air cleaner Clean Too high fuel level in Adjust float bowl gt Worn piston piston Replace rings Stuck piston rings Clean or replace Check carburetor Check for plugged Worn cyl bore Bore or replace fuel line lnsufficient cyl head Retighten Check for plugged air tightening passage Faulty contact of Lap valve seat Plunge up by valve Warped cyl head Check float level Check carb setting Adjust valve clearance Broken valve spring Replace Stuck valve Clean or replace Burned head gasket Replace www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING 8 3 Engine Troubleshooting Guide Engine loss power Is engine overheated YES gt NO Is the ignition spark
5. 43 0 mm MAX 1 693 in MAX 37 95 38 05 mm 1 4941 1 4980 in e The crankpin surface should be concentric and parallel to each other within 0 006 mm 0 0002 in full indicator reading e Finish the crankpin surface with a super finishing stone 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 7 1 Electrical System Table of Contents Exploded Mi Wii AN IE p s ad 7 2 SN O a T 7 3 Wiring Diagr Meie ni irae a anai aa A oa a s 7 4 POCA US E A EE AA cae es ee ad ee ee Pv es ee 7 5 Ghargi a Ignition Systems cedida adie needs eos adler octane os eta es ee dae erate eae isla 7 6 Flywheel Stator Coil Removal siise a aa ii 7 6 Flywheel Stator Coil Installation ccccccccccesesceeseececeeeeeceeeeseaeeeceneeeceeeesaaeessaaeeseseesecaeesseaeesseaeesseneesseseeseueeessiseessaes 7 7 Charging System Operational INSP CtION c ceceeeeeeeeeeeeeeeseeeaeeceeceaeeeaeeeaeeceeeseaeesaeecaeseaeeeaeeseeseaeseaeeseeseaeseaeenaees 7 9 Stator Goll Resistance 4 1s snes tlie she ai leit a ie nai ade ea ett aha 7 9 Unregulated Stator Outputs iai ale ee oe Ghee cee die abe oi eee 7 9 Regulator Removals iuccctnk tines ay A eee ee ee e 7 10 Regulator Installation lt td rain TS 7 10 Regulator Resistance A a ali 7 10 Ignition Coll Removal tii basico 7 13 Igniti
6. 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 Note the position of the connecting rod caps for reinstalling 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 connecting rod No 1 cyl K mark on the connecting rod is face to face with No 2 cyl K Mark on the connecting rod Keep parts together as a set e Remove one of the piston pin snap rings A with needle nose pliers B e Remove the piston by pushing the piston pin A out the side from which the snap ring was removed e Remove the top and second rings with piston ring pliers Special Tool Piston Ring Pliers 57001 115 e l the special tool is not available carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it e Remove the 3 piece oil ring with your thumbs in the same manner 6E16060651 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 4 17 Cylinder Piston Piston Installation e Install the expander A in the piston oil ring groove so that the B expander ends B touch together never overlap e Install the upper and lower steel rails T
7. 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 an oil to the threads seated surface or washer S Tighten the fasteners following the specified sequence SS Apply silicone sealant Fastener Torque ft lb Fuel System Choke Valve Screw 0 95 0 097 8 4 in lb Throttle Valve Screws 0 95 40 097 8 4 in lb Plug Main Jet 18 1 8 13 Drain Screw Carburetor 2 0 0 2 18 in lb Fuel Shut Off Solenoid Valve Carburetor 19 1 9 14 Float Chamber Mounting Screw Carburetor 4 0 0 4 35 in lb Governor Arm Clamp Nut 7 8 0 8 69 in lb Governor Shaft Plate Screws 2 0 0 2 17 in lo Carburetor and Intake Pipe Mounting Bolts and Nuts 5 9 0 6 52 in lb Intake Manifold Mounting Bolts 5 9 0 6 52 in lb Air Cleaner Body Mounting Bolts 5 9 0 6 52 in lb Control Panel Mounting Bolts 5 9 0 6 52 in lb Cooling System Screen Bolts 5 9 0 6 52 in lb Engine shroud Bolt M8 on Cylinder Head 6 9 0 7 61 in lb Engine shroud Bolts M6 5 9 0 6 52 in lb Engine Top End Cylinder Head Bolts 28 2 8 21 Valve Clearance Lock Screws 6 9 0 7 61 in lb Connecting Rod Big End Cap Bolts 9 8 1 0 87 in lb Rocker Arm Bolts 28 2 8 21 Rocker Cover Mounting Bolts 6 9 0 7 61 in lb Muffler Flange Nuts 15 1 5 11 Spark Plugs 22 2 2 16 Remarks www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 1 8 GENERAL
8. If the runout exceeds the service limit replace the rod Rocker Arm Push Rod Runout Service Limit 0 5 mm 0 02 in Valve Mechanism Removal installation e Remove the cylinder head assembly see Cylinder Head Assembly Removal NOTE O When removing the valve mechanism parts note their position so that they may be reinstalled in their original position during assembly e Remove Valve Clearance Adjusting Nuts A Rocker Arms B e Support the valve head in the combustion chamber with a suitable block e To remove the spring retainer A push down the spring retainer with thumbs and remove the collets B e Remove the spring C and valve D e Remove the stem seals A NOTE O It is not necessary to remove the stem seal unless it is being replaced O Valve guide B is not replaceable do no remove it www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 10 ENGINE TOP END Cylinder Head e Valve Installation O Apply engine oil to the valve stem to avoid damaging the stem seal O Check to see that the valve moves smoothly up and down in the guide O Check to see that the valve seats properly in the valve seat If it does not repair the valve seat e Rocker Arm Installation O Apply engine oil to the spherical pivot seat area on the rocker arm O Apply engine oil to the rocker arm where it touches the push rod and valve stem end I
9. see Engine Top End chapter e Upside down the engine e Remove the camshaft A e Remove Washer A Snap Ring B Sleeve C Governor Plate D Snap Ring B Steel balls E Ball Guide F Ball Plate G Governor Assembly Installation e Fit the snap rings A into the grooves securely e Spin the governor plate by hand and check that the steel balls and governor plate operate freely www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 2 7 Governor Link Mechanism Governor Assembly Inspection O Visually check all governor parts for wear and damage If any parts are worm or damaged replace them Governor Shaft Removal e Split the crankcase see Camshaft Crankcase chapter e Unscrew the governor shaft plate screws A and pull out the governor shaft B outside NOTE O It is not necessary to remove the governor shaft unless it is being replaced e Replace the oil seal only if the lip shows signs of leakage or it has been damaged e When replacing the oil seal A of the governor shaft note the following O Install the oil seal into the crankcase cover B after the governor shaft is inserted in the cover and so that the marks C face out O The depth D is 0 2 mm 0 0 08 in Governor Shaft Installation e Apply engine oil to the governor shaft e Insert the governor shaft into the crankcase e Install
10. 0 40 kgf m 35 in Ib If the oil pressure is below the specification inspect the oil pump and relief valve If the oil pump and relief valve are not at fault inspect the rest of the lubrication system Oil Pressure 241 to 310 kPa 35 to 45 psi Oil Pressure Switch PT 1 8 Taper Pipe Threads Oil Pressure Switch Inspection When the oil pressure falls below 98 kPa 14 2 psi the oil pressure switch activates the oil warning lamp to alert the operator or lubricating problem e To check the oil warning system insert the switch key into the OFF position of the engine switch then turn it to the RUN position The warning light must be illuminated e When the engine is running be sure the warning light is OFF x If the warning light comes on stop the engine immediately and check the oil level e When starting the engine note the warning light on dash carefully x If the warning light is on in the started engine in spite of adequate oil level check the lead from the pressure switch to the warning light for short circuit and or check the pressure switch and replace damaged part If 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 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LUBRICATION SYSTEM 5 9 Oil Pump Relief Valve Oil Pump Relief Valve Removal e
11. 54 L and R 56 L and R 1 4 91 4 91 1 91 1 1 5 8 1 1 4 Float parallel to carburetor body Idle Speed 1 Low idle speed High idle speed Air Cleaner Type Pre cleaner Second stage cleaner Fuel Fuel requirement 1550 r min rpm 3600 r min rpm Dual stage filtration system Foam element Paper element Unleaded regular grade gasoline Fuel Pump Type Pulse diaphragm pump Governor Type Flyweight all speed governor 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 FUEL SYSTEM 2 5 Governor Link Mechanism Control Panel Assembly Removal e Remove Air Cleaner see Cleaner Body Removal Air Cleaner Mount Bracket Bolts A Air Cleaner Mount Bracket B 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 end from the choke lever C Control Panel Assembly Installation e Before installing the control panel assembly check to see that the choke lever A and engine speed control lever B move smoothly in all directions x If any part is worn or damaged replace the control panel assembly e After installation adjust the low idle speeds and high idle speeds to the specifications see Low Idle Speed and High Idle Speed adjustment
12. Dirt Before removal and disassembly clean the engine Any dirt entering the engine carburetor or other parts will work as an abrasive and shorten the life of engine For the same reason before installing a new part clean off any dust or metal filings 2 Battery Ground Remove the ground lead from the battery before performing any disassembly operations on the equipment This prevents a the possibility of accidentally turning the engine over while partially disassembled b sparks at electrical connections which will occur when they are disconnected c damage to electrical parts 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 espe
13. e Using a strap wrench or oil filter wrench A remove the oil filter B Special Tool Oil Filter Wrench 57001 1249 O When unscrewing the oil filter place a suitable container beneath the oil drip tray to receive oil from the oil filter and oil passages in the engine Turn the filter counterclockwise to remove it Oil Filter Installation e Apply light film of engine oil to the seal A e Install new filter O Turn the filter until the seal contacts mounting surface B of the engine Then turn the filter BY HAND S 3 4 turn more e Run the engine at slow idle speed 2 minutes Check for leaks around the engine e Stop the engine Check the oil level see Oil Level Inspection Oil Cooler Removal FH721D e Remove the oil filter see Oil Filter Removal e Unscrew the moutng joing A and remove the oil cooler B e Check the O ring C in groove of the oil cooler for damage Replace the O ring with a new one if necessary Oil Cooler Installation FH721D e Instal the oil cooler with the mounting joint and tighten it Oil Cooler Mounting Joint 44 N m 4 5 kgf m 33 ft Ib e Install the oil filter see Oil Filter Installation Torque lt Ambient Temperature _ gt 10C 200 30 C 40 C 20 C 10 C 0 C IN SAE10W 30 SAE10W 40 eo Rn AF 14 F 32 F 50 F 68 F 86F 104 F FH721D01S1 www mymowerparts com For Kawasaki Discount Parts C
14. throttle valve by hand Does the revolution drop or does engine stall at a certain position YES NO gt Y gt Plugged in carburetor interior Disassemble and clean Y Is air sucked through carburetor or intake manifold flanges YES Loose flange nuts Damaged gasket H Retighten H Replace NO Y Are valve clearances of normal values NO gt OCompression leakage Wrong valve timing Adjust valve clearance H Correct alignment of YES Y timing gear marks Y Is alignment of timing gear marks correct NO Largely deviated valve timing Correct alignment of timing gear marks www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING 8 5 Engine Troubleshooting Guide Fuel consumption is excessive Is compression sufficient p Oil consumption is excessive Is compression sufficient Engine backfires m YES gt NO ES gt TY ee Engine knocks Broken piston ring Replace gt Loose carb or intake manifold Tighten Loose cyl head or leaking head Tighten gasket Burned or sticking intake valve Replace Faulty ignition coil Replace Carb not properly adjusted Adjust gt Stale fuel Change Excessive carbon deposit in Clean engine Exce
15. 0 0233 in 6 08 mm 0 239 in 31 0 in 1 22 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 ZOO DH Piston pin hole inside diameter 16 08 mm 0 633 in Connecting rod small end inside diameter 16 05 mm 0 632 in Cylinder inside diameter Standard Cylinder 75 28 mm 2 964 in 0 50 mm Oversize 75 78 mm 2 983 in Cylinder bore out of round 0 056 mm 0 0022 in Standard Valve clearance Intake Exhaust 0 1 to 0 15 mm 0 004 to 0 006 in Valve seating surface angle Intake Exhaust 45 Valve seating surface width Intake 0 8 to 1 4 mm 0 03 to 0 06 in Exhaust 1 1 to 1 6 mm 0 04 to 0 06 in Intake Exhaust 6 00 to 6 012 mm 0 2362 to 0 2367 in Valves guide inside diameter Cylinder bore diamter standard cylinder Standard cylinder 75 18 to 75 20 mm 2 960 to 2 961 in 75 68 to 75 70 mm 2 979 to 2 980 in 0 50 mm Over size Special Tools Compression Gauge 57001 221 Compression Gauge Adapter M14 x 1 25 57001 1159 Piston Ring Pliers 57001 115 Piston Ring Compression Grip 57001 1095 Piston Ring Compression Belt 467 79 57001 1097 Valve Seat Cutter Holder Bar 57001 1128 Valve Seat Cutter Holder 46 57001 1360 Valve Seat Cutter 45 635 0 57001 1116 Valve Seat Cutter 32 433 0 57001 1199 Valve Seat Cutter 32 430 0 57001 1
16. 2 20 Cleaner Body StA O oia ire Lanas AE Sa 2 20 Housing Cover and Body INSPeCtiOn ecceeeceseeeeeseceseeseeeeeneeeaeeeseeceaeeeaeeeseecaeeeaeeeaeecsaeseaeseaeesaeeseaeeeaeeseeseaeeeaeeeaes 2 20 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 2 FUEL SYSTEM Exploded View 228 830P2002W4 C 1 Pilot Screw T1 0 95 N m 0 097 kgf m 8 4 in lb 2 Pilot Air Jet T2 0 98 N m 0 1 kgf m 8 7 in lb 3 Main Air Jet T3 2 0 N m 0 2 kgf m 18 in lb 4 Main Jet T4 3 4 N m 0 35 kgf m 30 in Ib 5 Pilot Jet T5 5 9 N m 0 6 kgf m 52 in Ib 6 Solenoid Valve T6 19 N m 1 9 kgf m 14 ft lb www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 2 3 Exploded View O Apply engine oil T1 2 0 N m 0 2 kgf m 17 in lb T2 5 9 N m 0 6 kgf m 52 in Ib T3 7 8 N m 0 8 kgf m 69 in Ib www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 4 FUEL SYSTEM Specifications Caburetors Specifications Make type Throttle bore diameter Venturi diameter Main Jet MJ Pilot jet PJ Main air jet MAJ Pilot air jet PAJ Pilot air screw turns out PS Idle mixture screw turns out Float level Standard FH601D FH641D FH680D FH721D Nikki 13Y244 Nikki 621266 24 mm 0 94 in 26 mm 1 02 in 18 mm 0 71 in 21 mm 0 83 in L 92 R 95 108 L and R
17. AA A i n 6 5 GIGANING aci da tai al da as 6 6 Brote A eo dete se ele 6 7 Breather Valve Re MOVA anar t a Tr va cabaedesaesen sadue qehscasunachuuginensagetdesiacesasegsancqei ps scaganenagsesahassisedusdenacseancaeeiansices ies 6 8 Breather Valve INSpection ia wenvcadr tered ty ele de een ee ee is Bd nee eae RS 6 8 Breather Valve Install yv A Aaa 6 9 Camshaft Tapp tied citi ao a a a 6 10 Camshaft Tappet RemoValiiiviocoodo pira an aii 6 10 Camshaft Tappet Installation 0cc cintia 6 10 Gamshaft Disassembly vc cociatarasmarnri ir a ed aaee E ededi aaia a denka 6 11 Cams aft Assembly 3 serari ienr A E A E AE KSA 6 11 Camshaft Inspector ON 6 11 Camshaft Bearing Journal Wear ccceecccecceeeeeeeeeeeeeceaeeeeeeeaeeseeeeaeeeaeeceaeeaeeeaeesaeeseeeseaeesaeeseesneeeeaeseeeeeneeseaeeeeeeeeetea 6 11 Grankshaft Connecting m1010 PAESE EEA A E A T 6 13 Connecting Rod Removals inanar rr ad E tive dl ase a Eaei dass 6 13 Connecting Rod Installation sisser a e a E E ENE 6 13 Grankshaft Removal sensi sneen aieeaa ena edie daea Saa dieat EEEN NE ee brand nance eee ais 6 13 Grankshaftlnstalatio Mss ea a E ana EE ahaa 6 13 CleANING AMSPSCHOM O 6 13 Connecting Rod Bend TWISt cisminin a 6 13 Connecting Rod Big End Crankpin Width Wear cccccceceeseeeeeeeeeeeeeeeeaeeeseeseneseaeecaeesieesaeeeaeeseesneeeeaeeseeeneeeeaeenas 6 14 Connecting Rod Big End Bearing Crankpin Weal c ccecceeeeeeereceeeeaeeeaeeeeeeeeaeeeaeeeaeeseeeenee
18. Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 6 13 Crankshaft Connecting Rod Connecting Rod Removal e Remove Piston see Engine Top End Chapter Connecting Rod Installation e Install Piston see Engine Top End chapter Crankshaft Removal e Set the engine on a clean surface while parts are being removed e Drain the oil see Lubrication System chapter e Remove Flywheel see Electrical System chapter Camshaft see Camshaft Tappet Removal Connecting Rod and Piston Assembly see Engine Top End chapter e Pull the crankshaft A out of the crankcase Tap gently with a wooden or plastic mallet if necessary to loosen the crankshaft Crankshaft Installation e Clean up the crankshaft and crankcase thoroughly especially 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 oil seal in the crankcase Cleaning Inspection e After removing clean the crankshaft and connecting rods with a high flash point solvent and dry them with compressed air e Inspect the teeth of the crankshaft gear for pitting fatigue cracks burrs and evidence of improper tooth contact Replace the gear if necessary e Inspect the crankshaft and connecting rods especially at the bearing surfaces for wear scratches evidence of improper contact or other d
19. Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 6 7 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 emission control system is used to eliminate blow by gases The blow by gases are led to the breather chamber through the crankcase and the camshaft Then it is drawn into the clean side of the air cleaner through the cylinder head and the hose and mixed with the clean air flow and subsequently coming into the combustion chamber through the carburetor and the intake manifold Oil is primarily separated from the gases while passing through the inside of the rocker chamber from the crankcase and secondly separated from the gases in the breather chamber and then returned back to the crankcase cover lt i Fresh Air 4 Blow by Gass Oil To Cylinder Head gt A LA Ark AA BO www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 8 CAMSHAFT CRANKSHAFT Breather Breather Valve Removal e Remove the bolts A and breather chamber cover B e Remove the pipe A e Remove the breather valve B unscrewing the mounting screws A at the cam gear side of the crankcase see Camshaft Tappet Removal Breather Valve Inspection e Visually inspect the reed valve A for breakage hair cracks or disto
20. Indicated on the Wiring Diagram Red Wire Strands Yellow Red Y pa Yellow Red 6B020601W1 18 Replacement Parts When there is a replacement instruction replace these parts with new ones every time they are removed There replacement parts will be damaged or lose their original function once removed 19 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure 20 Specifications Specification terms are defined as follows Standards show dimensions or performances which brand new parts or systems have Service Limits indicate the usable limits If the measurement shows excessive wear or 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 Model Identification Cylinder Number Designation No 1 Cylinder is on the electric starter side No 2 Cylinder is on the oil fileter side www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 5 General Specifications Type of engine Cylinder layout Bore x Stroke Piston displacement Direction of rotation Compression r
21. Installation e Clean the mating surfaces of the carburetor and intake manifold and fit the new gaskets e Take care not to bend the throttle and choke link rods during installation Make sure the link spring around the throttle link rod is inplace and that it pulls the governor arm and carburetor throttle shaft lever toward each other e Install the intake manifold A new gaskets B insulator C carbu retor D and intake pipe E sequence as shown e Tighten the carburetor mounting bolts and nuts Torque Bolts and Nuts 5 9 N m 0 6 kgf m 52 in Ib e Adjust Carburetor Pilot Screw Idle Speed www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 2 13 Carburetor Carburetor Disassembly Assembly e Refer to the illustration shown for disassembly and assembly e There are several passage plugs Ball plugs in the carburetor body Do not remove e Before disassembly mark the outside of choke valve and throttle valves for assembling them e Replace the pilot screw in accordance with the following procedure if necessary O Carefully 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 O Remove the limiter Be careful not to turn pilot screw at this point Turn the pilot screw clockwise and count the number of turns until screw is gently seated in the pilot passage Record the numb
22. Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 16 ELECTRICAL SYSTEM Starter System Starter Motor Assembly e Assembly is the reverse of disassembly e Apply a small amount of grease A to the armature shaft e Do not reuse the snap ring B Replace it with a new one e Check the cap and replace it with a new one if damaged e Fit the projection A on the bracket into the notch B in the yoke e Press the springs and holding the brush leads with suitable 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 If the brushes are shorter than the service limit replace them Brush Length Service Limit 6 4 mm 0 25 in Brush Spring Inspection e Inspect the brush springs for pitting cracks rusting and burrs Replace the spring if necessary e Inspect the springs for weakened conditions and distortion x Replace the springs if necessary If the brush springs are able to press the brushes firmly into place they may be considered serviceable If they cannot replace them Armature Inspection e Inspect the surface of the commutator A 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
23. Limit 0 2 mm 0 008 in e Measure the outside diameter A of the outer rotor with a micrometer at several points x If the rotor diameter is less than the service limit replace both the inner and outer rotor Outer Rotor Outside Diameter Service Limit 40 470 mm 1 5933 in e Measure the thickness B of the outer rotor with a micrometer at several points If the rotor thickness is less than the service limit replace both the inner and outer rotor Outer Rotor Thickness Service Limit 9 830 mm 0 3870 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 10 LUBRICATION SYSTEM Oil Pump Relief Valve e Measure the inside diameter A of the pump housing with a inside micrometer at several points If the inside diameter is more than the service limit replace the crankcase cover Pump Housing Inside Diameter Service Limit 40 801 mm 1 6063 in e Measure the depth B of the pump housing with a depth micrometer at several points If any of measurement is more than the service limit replace the crankcase cover Pump Housing Depth Service Limit 10 230 mm 0 4028 in e Measure the outside A diameter of the pump shaft with a micrometer at several points If the diameter is less than the service limit replace the pump shaft Pump Shaft Outside Diameter Service Limit 10 923 mm 0 4300 in e Measurer the inside diameter A of the pump shaft bearing in t
24. NO gt normal YES Is lubricationg condition NO gt normal YES Is unusual smoke emitted YES gt out of muffler NO Is compression sufficient NO gt Engine runs erratically Problem in the system lack of fuel fuel m Crankcase low on oil Adjust level or add Too much oil in crankcase Adjust level Excessive engine load Decrease load Carb not properly adjusted Adjust Carbon deposit in combustion Clean chamber Clogging of cooling system Clean Damaged cooling fan Replase Wrong spark plug Replace Faulty ignition coil Replace Incorrect air gap Adjust gap O Too much or too little oil in Correct crankcase Excessively contaminated lub Change ricating oil O Defective oil filter Replace Faulty relief valve Replace Faulty oil pump Replace O Clogging oil system Clean Plugged air cleaner Clean Carbon deposit in exhaust hole Clean and muffler Carb not properly adjusted Adjust Too much oil in crankcase Adjust level Worn piston piston rings Replace Worn cylinder bore Bore or replace See Engine Starts Hard O Spark plug fouled pitted or Replace or adjust gapped incorrectly O Entry of dust or water into fuel Clean pipe or fuel filter Air or vapour lock in fuel line Clean O Plugged air vent of fuel tank Clean cap Plugged air fuel passes in carb Clean O Too little opening of carb pilo
25. Remove the crankcase 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 ball e Disassemble the pump parts assembly A Pin B Pump Gear C Mounting Bolts D Outer Rotor E Inner Rotor F Pump Shaft G Relief Valve Ball H Spring I Pump Cover Plate J 6 mm DIA Hole Oil Pump Relief Valve Installation e Fill the rotor housing with engine oil for initial lubrication e Install the relief valve ball and spring in position then install the pump parts assembly in the crankcase cover NOTE O When 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 lb Oil Pump Relief Valve Inspection e Remove the oil pump see Oil Pump Relief Valve Removal e Visually inspect the pump gear outer and inner rotor and cover plate If there is any damage or uneven wear replace them O Check the clearance A between the inner and outer rotor with a feeler gauge Measure the clearance between the high point of the inner rotor and the high point of the outer rotor x If the measurement exceed the service limit replace the rotors as a set Inner and Outer Rotor Clearance Service
26. SYSTEM Specifications pom Standart Engine Oil Grade API Service Classification SF SG SH or SJ class Viscosity SAE40 SAE30 SAE10W 30 SAE10W 40 or SAE5W 20 Capacity 1 4 L 1 5 US qt When oil filter is not removed 1 6 L 1 7 US qt When oil filter is removed Level Between H and L marks on oil gauge Oil Pressure 241 to 310 kPa 35 to 45 psi Oil Pressure Switch Detect pressure 98 kPa 14 2 psi Screw PT 1 8 pipe thread Oil Filter By pass Valve Openning Pressure 78 5 to 117 5 kPa 11 4 to 17 1 psi tem Service Limit Oil Pump Inner and outer rotor clearance 0 2 mm 0 008 in Outer rotor outside diameter 40 470 mm 1 5933 in Outer rotor thickness 9 830 mm 0 3870 in Pump housing inside diameter 40 801 mm 1 6063 in Pump housing depth 10 230 mm 0 4028 in Pump shaft outside diameter 10 923 mm 0 4300 in Pump shaft bearing inside diameter 11 072 mm 0 4359 in Relief valve spring free length 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 5 5 Engine Oil Oil Filter and Oil Cooler CAUTION Engine operation with insufficient deteriorated or contami nated engine oil will cause accelerated wear and may result in engine seizure and accident Before starting the engine for the first time add oil T
27. ed replace the regulator PEO oe iv A a O ff Y f oy O l TY o 1 teo toll y Y DO www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 12 ELECTRICAL SYSTEM Charging Ignition System This engine ignition is controlled by a solid state ignition assembly and requires no periodic maintenance 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 SW Stop Switch Flywheel F a a SS M Magnet CW Rotation N North Pole S South Pole Ignition Theory of Operation Mounted to the periphery of a flywheel are a pair of magnetic poles south leading in clockwise rotation generated by a permanent magnet By rotating the flywheel magnetic poles clockwise past the ignition module on a laminated core group a voltage is generated in the primary winding L1 This generates a small bias current to flow through the control resistor R1 to the base of Q1 This base drive causes the transistor to conduct turns on completing the primary circuit Current flows from the high side of the primary winding through the transistor collector to emitter to ground Th
28. in 20 45 mm 0 805 in 43 1 mm 1 697 in Connecting rod big end inside diameter 40 044 mm 1 5765 in 39 940 mm 1 5724 in 0 05 mm 0 002 in TIR 39 896 mm 1 571 in 39 896 mm 1 571 in Crankpin Outside diameter Crankshaft runout PTO side Flywheel side Crankshaft journal diameter Crankcase PTO shaft bearing inside diameter Crankcase cover 40 15 mm 1 581 in Crankshaft journal bearing inside diameter Crankcase 40 15 mm 1 581 in Sealant Kawasaki Bond Silicone Sealant 56019 120 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 4 CAMSHAFT CRANKSHAFT 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 O There are two knock pins on the crankcase mating surface A wooden or plastic mallet may be used to gently tap loose the crankcase cover Crankcase Cover Installation e Chip off the old gasket from the mating surfaces of the crankcase and cover e Using compressed air blow out the oil passage in the crankcase cover e With a high flash point solvent clean off the mating surfaces of the crankcase and cover and wip
29. performed CAUTION Do not adjust high idle speed with the air cleaner removed e Start and warm up the engine thoroughly AWARNING Always keep your hands clear of the moving parts e Move the throttle lever at a dash to the high idle position and match the lever hole position with the panel hole by inserting 6 mm dia pin or bolt A e Loosen two M6 control panel mounting bolts B enough to move the control panel assembly e Carefully move the control panel assembly right side C up or down to obtain the specified high idle speed High Idle Speed 3600 rpm e Tighten the M6 mounting bolts Torque Control Panel Mounting Bolts 5 9 N m 0 60 kgf m 52 in Ib e Remove the 6 mm dia pin or bolt e Check the idle speed and readjust the idle speed if necessary CAUTION Be sure to make the idle and high idle speeds respectively correspond to those of the equipment www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 2 11 Carburetor High Altitude Operation At high altitude the standard carburetor air fuel mixture will be excessively rich Performance will decrease and fuel consumption will increase High altitude performance can be improved by installing a smaller diameter main jet in the carburetor and correct idle speed NOTE The main jet high altitude kits are available if the equipment is to be used in the high altitudes The main jet
30. removed with new ones as removal deforms and breaks them 16 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film During assembly oil or grease whichever is more suitable should be applied to any rubbing surface which has lost its lubricative film Old grease and dirty oil should be cleaned off Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles Don t use just any oil or grease Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended This manual makes reference to molybdenum disulfide grease MoS2 in the assembly of certain engine parts Always check manufacturer recommendations before using such special lubricants 17 Electrical Wires All the electrical wires are either single color or two color and with only a few exceptions must be connected to wires of the same color On any of the two color wires there is a greater amount of one color and a lesser 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
31. severe the both cylinders must be bored oversize and oversized pistons installed www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 4 19 Cylinder Piston Piston Cleaning e Remove the piston and piston rings see Piston Removal CAUTION Never clean the piston head with the engine assembled Carbon particles will fall between the piston and cylinder and damage the crankshaft bearings e Scrape the carbon off A the piston head e Use the scraping tools carefully Do not gouge the piston head To avoid gouging use scrapers that are made of a material that will not cause damage e Clean the piston ring grooves A with a broken piston ring or other suitable tools CAUTION Be careful not to widen the ring grooves Damaged ring grooves will require piston replacement Piston Ring and Ring Groove Wear e Clean the piston see Piston Cleaning e Visually inspect the piston rings and ring grooves x If the piston rings are worn unevenly or damaged replace them If the ring grooves are worn unevenly or damaged replace both the piston and piston rings e Check ring grooves for wear by inserting a new ring in the proper groove at several points around the piston e Measure the clearance between the top and second rings and their grooves using a thickness gauge A If the piston ring groove clearance is greater than the specified value replace
32. 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 carburetor or the floats may be crushed by the pressure Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carburetor with a cleaning solution This will prevent damage to or deterioration of the parts The carburetor body has plastic parts that cannot be removed Do not use a strong carburetor cleaning solution which could attack these parts instead use a mild high flash point clean ing solution safe for plastic parts Do not use wire or any other hard instrument to clean carbu retor parts especially jets as they may be damaged Disassemble the carburetor Immerse all the metal parts in a carburetor cleaning solution Rinse the parts in water and dry them with compressed air 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 Carburetor Inspection AWARNING Gasoline is extremely flammable and can be explosive under certain Turn the ignition switch OFF Do not smoke Make sure the area
33. the cylinder head e Pitted or worn valve seats can be refaced Lap the valves to the seats after refacing e Coat the valve seat with machinist s dye e Push the valve into the guide e Rotate the valve against the seat with a 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 O The 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 Valve Seating Surface Width STD Good Too Wide Inlet 0 8 1 4 mm 0 03 0 05 in Exhaust 1 1 1 6 mm 0 04 0 06 in Too Narrow Uneven Valve Seat Repair e Follow the manufacture s instructions for use of valve seat cutters Special Tools Intake Valve Seat Cutter 45 935 0 57001 1116 Outside Cutter 32 933 0 57001 1199 Exhaust Valve Seat Cutter 45 930 0 57001 1187 Outside Cutter 32 930 0 57001 1120 Valve Seat Cutter Holder 6 0 57001 1360 Valve Seat Cutter Holder Bar 57001 1128 x If the manufacture s instructions are not available use the following procedure Seat Cutter Operating Cares 1 This valve seat cutter is designed only for valve seat repair Therefore the cutter must not be used for other purposes 2 Do not drop or hit the valve seat cutter or the diamond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter bef
34. the governor shaft plate A to the shaft B as shown Torque Governor Shaft Plate Screws 2 0 N m 0 20 kgf m 17 in Ib e Check that the governor shaft moves freely in its operating range NOTE O If the oil seal is removed oil seal is put on after shaft is installed www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 8 FUEL SYSTEM Carburetor Fuel and Air Flow Main System Fuel and Air Supply 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 Air Cleaner main nozzle where it is joined by air from the main air passage main Fuel air jet The resulting mixture flows out the end of the main nozzle into Tank the carburetor bore where it is atomized by the high speed air flow and S carried into the engine Float Main Air Carburetor Passage Bore Main Nozzle The pilot system includes the pilot jet F pilot air screw G Idle Pilot System Fuel and Air Suppiy mixture screw pilot air jet H pilot outlet I and the bypass holes J Fuei gt Float Main Tank Chamber Jet The pilot system meters the fuel air mixture while the engine is idling and running under a light load Und
35. the piston Piston Ring Groove Clearance Service Limit Top 0 18 mm 0 007 in Second 0 16 mm 0 006 in NOTE The oil ring is a three piece assembled ring Difficult to measure the ring groove clearance and thickness visually inspect only e Measure the piston ring thickness A O Use a micrometer to measure at several points around the rings x If any of the measurement are less than the service limit replace the entire set of rings Piston Ring Thickness Service Limit Top Second 1 40 mm 0 055 in NOTE O When using new rings in a used piston check for uneven groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 20 ENGINE TOP END Cylinder Piston Piston Ring End Gap e Remove the piston rings e Push each ring one at a time in the cylinder bore to a point close to the bottom of the cylinder bore O Use 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 If the end gap of any ring is greater than the service limit replace the entire set of rings Piston Ring End Gap Service Limit Top 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 diame
36. tiesin 5 8 Oil Pressure Switch Inspection iieii A E a E e is 5 8 Oil P mp Relief ValVe matisse piitsa dd aad 5 9 Oil Pump Relief Valve Removal sinemi eiiiai esete otecbesceve eine seniade eneako eeke ita aa aeina e E aN aiee 5 9 Oil Pump Relief Valve Installation cccccccccsscceeseeeeeeeeeeeeeceeaeeeseneeeceaeeseceeenaneescaeeeseeeescaeeeseaeesseaeeessaeeseneeeesiseeeees 5 9 Oil Pump Relief Valve INS pecto miiirn maea eree aeea aa aE E aaa cnn a aa aa aE aE aa a aa EESE 5 9 ENARE AALA TEA A E E AATA AT ea 5 12 Oil Sereen Remato A id tt ve 5 12 Oil Screen OMAN data 5 12 GCleaning and ASEO ii tr 5 12 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 2 LUBRICATION SYSTEM Exploded View y o y ai j 830P5012W4 C O Apply engine oil T1 2 0 N m 0 2 kgf m 18 in lb G Apply grease T2 5 9 N m 0 6 kgf m 52 in lb S Follow the specific tighening sequence T3 6 9 N m 0 7 kgf m 61 in Ib SS Apply silicone sealant T4 See page 5 6 1 Other than FH721D Engine T5 25 N m 2 6 kgf m 19 ft lb 2 FH721D Engine T6 9 8 N m 1 0 kgf m 87 in lb T7 44 N m 4 5 kgf m 33 ft lb www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LUBRICATION SYSTEM 5 3 Engine Oil Flow Chart www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 4 LUBRICATION
37. 120 Valve Seat Cutter 45 30 0 57001 1187 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 6 ENGINE TOP END Cylinder Head Compression Measurement e Before measuring compression do the following Be sure the battery is fully charged O Thoroughly warm up the engine so that engine oil between the piston and cylinder wall will help seal compression as it does during normal running O Stop the engine e Disconnect the spark plug caps of each cylinder and remove the spark plugs e Attach the compression gauge assembly firmly into one plug hole Special Tool Compression Gauge 57001 221 A Compression Gauge Adapter 57001 1159 B e Ground the spark plugs to the engine AWARNING To avoid fire do not ground the spark plugs in proximity to the plug holes Keep the plugs as far away as possible from the plug holes e Using the starter motor turn the engine over with the throttle fully open until the compression gauge stops rising the compression is the highest reading obtainable Cylinder Compression MIN 390 kPa 57 psi e Repeat the measurement to the other cylinder If the compression is higher than the specified value the piston rings cylinder and valves are probably in good condition 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
38. 606 561 4983 ELECTRICAL SYSTEM 7 17 Starter System e Measure the depth of the grooves between the commutator segments x If the grooves are shallower than the specified limit replace the armature with a new one x If the grooves are only dirty clean them carefully Commutator Groove Depth Limit Less than 0 9 mm 0 035 in A Bad B Segment C Good D 0 9 mm 0 035 in limit E Mica e Measure the commutator outside diameter A at several points 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 Position a dial indicator perpendicular to the commutator e Rotate the armature slowly and read the commutator runout x If runout is more than the service limit 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 O Set the hand tester to the R x 1 Q range and measure the resistance between each segment A and all the others If the resistance it too high or even infinite the armature winding has an open circuit Replace the starter motor Armature Winding Resistance Close to 02 e Set the hand tester to the R x 1 kQ range and measure the resistance between the commu
39. AWARNING 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 disconnect negative lead from battery as soon as possible STARTER DOES NOT ROTATE Is click sound from NO gt Faulty battery Charge or replace solenoid switch Faulty leads or connection Repair or replace Melted fuse Replace Faulty engine switch Repair or replace Faulty solenoid switch Replace YES Weak battery Faulty leads or connection Solenoid to motor Faulty solenoid switch Main terminal in solenoid Faulty starter motor Charge or replace Repair or replace Replace Repair or replace STARTER ROTATES BUT SLOW Is battery normal and well NO gt OWeak battery H Charge or replace charged YES Faulty leads or connection Repair or replace Solenoid to motor Faulty solenoid switch t Replace Main terminal in solenoid Faulty starter motor Repair or replace Faulty engine E Repair or replace STARTER ROTATES BUT CAN NOT CRANK ENGINE Does pinion mesh with NO gt Worn pinion or ring gear Replace ring gear 6 incorrect starter alignment Correct YES Faulty pinion clutch Replace Faulty engine Repair or replace STARTER DOES NOT STOP IN ENGINE SWITCH OFF NO gt OFaul
40. For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FH601D FH641D Kawasaki FH680D FH721D 4 stroke air cooled v twin gasoline engine Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Department Consumer Products amp Machinery Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring 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 Kawasaki Heavy Industries Ltd 2000 2001 Third Edition 1 Jul 11 2001 K www mymowerparts com 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
41. INFORMATION Torque and Locking Agent Nm kgtm ftb Lubrication System Engine Drain Plugs Plastic 6 9 0 7 61 in lb Engine Drain Plug Metal 20 2 0 145 Engine Drain Plug Joint Plastic 17 1 7 12 Engine Drain Plug Joint Metal 39 4 0 29 Oil Pressure Switch 9 8 1 0 87 in lb SS Oil Pump Cover Plate Mounting Bolts 5 9 0 6 52 in lb Oil Filter see Page 5 6 in the text Camshaft Crankshatt Crankcase Cover Bolts 25 2 6 19 S Breather Chamber Cover Bolts 5 9 0 6 52 in lb Electrical System Stator Coil Screws 3 4 0 35 30 in lb Flywheel Bolt 56 5 7 41 Fan Housing Bolts M8 6 9 0 70 61 in lb Fan Housing Bolts M6 5 9 0 6 52 in lb Screen Bolts 5 9 0 6 52 in lb Regulator Screws 3 4 0 35 30 in lb Ignition Coil Bolts 5 9 0 6 52 in lb Starter Motor Mounting Bolts 15 15 11 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 mm ft lb 17 in lo 30 in lb 52 in lb 11 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 9 Special Tools Compression Gauge 57001 221 Valve Seat Cutter Holder 06 57001 1360 Valve Seat Cutter 45
42. all 606 678 9623 or 606 561 4983 LUBRICATION SYSTEM 5 7 Engine Oil Oil Filter and Oil Cooler Oil Cooler Cleaning FH721D e Clean dirt off the outside fins A with brush or with compressed air www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 8 LUBRICATION SYSTEM Pressurized Lubrication System The engine lubrication circuit is a pressurized system consisting of a positive displacement pump which picks up oil through a filter screen from the crankcase The oil is pumped to a replaceable oil filter cartridge through the engine s oil passages to lubricate internal components and return to the crankcase A pressure relief valve is used between the oil pump and oil filter to relieve excessive oil pressure by returning excess oil to the crankcase see Oil Flow Chart Oil Pressure Measurement e Remove the oil pressure switch or oil passage plug from the crankcase e Install an appropriately sized oil pressure gauge adapter A and oil pressure gauge B e Run the engine and allow warm up completely e Run the engine at fast idle speed and read the oil pressure gauge e Stop the engine e Remove the oil pressure gauge and adapter e Apply silicone sealant to the threads of the pressure switch and tighten it or tighten the plug Sealant Kawasaki Bond Silicone Sealant 56019 120 Torque Oil Pressure Switch 9 8 N m 1 0 kgf m 87 in Ib Oil Passage Plug 3 9 N m
43. amages x Replace them if necessary Connecting Rod Bend Twist e Measure connecting rod bend O Select an arbor of the same diameter as the connecting rod big end and insert the arbor through the connecting rod big end O Select an arbor of the same diameter as the piston pin and at least 100 mm long and insert the arbor through the connecting rod small end O On a surface plate set the big end arbor on V blocks O With the connecting rod held vertically use a height gauge to measure the difference in the height of the small end arbor above the surface plate over a 100 mm length to determine the amount of connecting rod bend If connecting rod bend exceeds the service limit the connecting rod must be replaced Connecting Rod Bend Service Limit 0 15 100 mm 0 006 3 94 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 14 CAMSHAFT CRANKSHAFT Crankshaft Connecting Rod e Measure connection rod twist O With the big end arbor still on the V blocks hold the connection rod horizontally and measure the amount that the small end arbor varies from being parallel with the surface plate over a 100 mm length of the arbor to determine the amount of connecting rod twist If connection rod twist exceeds the service limit the connecting rod must be replaced Connecting Rod Twist Service Limit 0 15 100 mm 0 006 3 94 in Connecting Rod Big End Crankpin Wid
44. as insufficient experience or doubts as to his ability to do the work all adjustments maintenance and repair should be carried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thoroughly familiarize yourself with the procedures before starting 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 engine e Follow the Periodic Maintenance Chart in the Service Manual e Be alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki engine parts Genuine 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 In preparing this manual we divided the product into its major systems These systems became the manual s chapters All information for a particular system from adjustment through disassembly and inspection is located in a single chapter The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in t
45. be bored to the next oversize and then honed see Cylinder Boring and Honing Cylinder Inside Diameter Standard 75 18 mm 75 20 mm 2 960 2 961 in Service Limit 75 28 mm 2 964 in 0 5 mm Oversize 75 68 75 70 mm 2 979 2 980 in Service Limit 75 78 mm 2 983 in Cylinder Bore Out of Round Standard 0 01 mm 0 0004 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 standard bore size If this is done accurately the stock oversize rings and piston will fit perfectly and proper clearance will be maintained Resizing the cylinder bore can be done by reliable repair shop or by using a drill press and honing tool Use the stone recommended by the hone manufactures to produce correct cylinder wall finish Machine bore first the bore diameters should be shown in the table Fine Boring Bore Diameter Oversize Bore Diameter 0 50 mm 75 65 to 75 68 mm 2 978 to 2 979 in Final Bore Diameter Oversize Bore Diameter 0 50 mm 75 68 to 75 70 mm 2 979 to 2 980 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 22 ENGINE TOP END Cylinder Piston Change to a honing stone for finishing the final bore diameter should be as shown in the table Be sure the correct stone is used and the stone is not worn e Clean the cylinder at the top and bottom of the cylinder to remove bu
46. cially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removal of screws held by a locking agent in order to avoid damaging the heads 6 Edges Watch for sharp edges especially during major engine disassembly and assembly Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over 7 High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent commonly available in North America is Standard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent 8 Gasket O Ring Do not reuse a gasket or O ring once it has been in service The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks 9 Liquid Gasket Non Permanent Locking Agent Follow manufacturer s 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 circum
47. ct a plastic tube A to the carburetor drain hole and place a suitable container under the plastic tube other end e Turn out the drain screw B a few turns to drain the carburetor and check to see if water or dirt has accumulated in the carburetor e Tighten the drain screw Torque Drain Screw 2 0 N m 0 2 kgf m 18 in Ib e f any water or dirt is found clean the carburetor see Carburetor Cleaning and fuel tank and check the fuel filter Carburetor Removal AWARNING Gasoline is extremely flammable and can be explosive 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 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 12 FUEL SYSTEM Carburetor e Remove Air Cleaner and Related Parts see Cleaner Body e Turn the fuel shut off valve to the OFF position e Drain the carburetor e Disconnect the fuel tube at the fuel inlet joint A of the carburetor e Remove the carburetor mounting bolts B and nuts C e Disconnect the solenoid valve lead terminal and remove the earth terminal e Unhook the throttle link spring B at the throttle shaft lever C clip end with a long nose plier e Unhook the throttle D and choke link rods E at the top ends of their arms while pull off the carburetor Carburetor
48. d suitable intervals The bullet mark designates that the corresponding item should be performed at that interval Some adjustments require the use of special tools or other equipment An electronic tachometer will facilitate setting idle and running speeds OPERATION INTERVAL Check or clean air intake screen Check and add engine oil Check for fuel and oil leakage Check for loose or lost nut and screw Check battery electrolyte level Clean air cleaner foam element 1 Clean air cleaner paper element 1 rr A cylinder head fins 1 Tighten nut and screws Change engine oil e Clean and re gap spark plugs Y Check and clean oil cooler fins a Change Oil filter Change air cleaner paper element 1 Check and adjust vlave clearance Clean and lap valve seating surface Clean combustion chamber 1 Service more frequently under dusty conditions These items must be performed with the proper tools See your authorized Kawasaki Engine Dealer for service unless you have the proper equipment and mechanical proficiency www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 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
49. d the variation on the dial gauge x If the stem runout is greater than service limit replace the valve Valve Stem Runout Service Limit IN EX 0 05 mm 0 002 in GE15011281 Valve Stem Diameter e Measure the diameter of the valve stem A in two directions at right angles at four different positions on the stem If any single measurement is less than the service limit replace the valve Valve Stem Diameter Service Limit Intake 5 95 mm 0 234 in Exhaust 5 93 mm 0 233 in Valve Guide Inside Diameter e Use a small bore gauge or a micrometer to measure the inside diameter A of the valve guide B a three places down the length of the guide If the measurement is more than the service limit replace the cylinder head with a new one Valve Guide Inside Diameter Service Limit Intake Exhaust 6 08 mm 0 239 in Valve Spring Inspection e Inspect the valve spring for pitting cracks rusting and burns Replace the spring if necessary e Measure the free length A of the spring If the measurement is less than the service limit replace the spring 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 4 16 ENGINE TOP END Cylinder Piston Piston Removal e Split the crankcase see Camshaft Crankshaft chapter e Remove the camshaft see Camshaft Crankshaft chapter
50. diana A es o ia tia 2 8 Fueltand Al Flo Wet A a ti Bee 2 8 Fuel Shut Off Solenoid Valve Electric Starter Model oocooonocicccniconncccnnccnnccnocnnncnconcconrcn anna crac 2 9 Low Idle Speed Adjustment inntrinn a 2 9 HighsIdle SpeedrAdjustment ica lil edA uik 2 10 High Altitude Operation aaa 2 11 Main Jeti Replacement ni idad 2 11 Fuel System Cleanliness Inspection ecceecceececeeeseeeeneeceeeeeeeceaeeeseeeaeeceaeeeaeesaeecsaeseaeesaeesaeeseaeesseeseeseaeeeaeesieeeneeeeas 2 11 Carburetor Removal iii even EE ETEV TEE EE eile 2 11 Carburetor Install A A A shar tcbanisbashanaredsceadats 2 12 Carburetor Disassembly ASSOMDIY esceescessceceneeeseeeneeteneeeaeeeaeecaaeeaesaeesseeseeseaeesseesaaeeaaeseaeeseeseeeseaeeseeeneeenaeeeas 2 13 Carburetor Gleaming 2 45 57 s4sc ices O Oia dal AGS deL E Ati ste 2 14 Carburetor Inspection dado 2 14 Fuel Shut Off Solenoid Valve TeSt c oooniii na a i 2 15 Intake MANOA a E a a a a iaa 2 16 Intake Manifold Removal cocinas e ic cada 2 16 Intake Manitold Installation oasis da 2 16 Intake Manitold Inspection aer 2 17 Fuel Pump Fuel Filter iii AA Sen eel 2 18 Fuel PUMP INSPectOn lt rrvacco cdta a as lil 2 18 F el Filter Inspection naa niveau dae 2 18 O A O A athe folate haata ira grs 2 19 Element Removal ict cassette etd tato dota 2 19 Element Installation diia A A 2 19 Element Cleaning and INSpectiON sinnini na ee a a e a a aa a N a aE 2 19 Cleaner Body Removal miii aii
51. e replace the pinion clutch www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING 8 1 Troubleshooting Table of Contents Engine Troubleshooting Guides des aee etic din daa Attia dna andthe neath bid 8 2 Starter Motor Troubleshooting Guide cccccccecececcsescecseeeeceeeeeeeseeeeeeeaeeeseeeaeeeneessaeseaeesnaessaeseaaeeaeesaeeeaaeeaeesarseaeneneeenertags 8 6 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 2 TROUBLESHOOTING Engine Troubleshooting Guide If the engine malfunctions check if the way the engine is used is correct If engine malfunctions even if engine is used correctly systematically carry out troubleshooting starting with simple points This chart describes typical troubleshooting procedures Do not unnecessarily disassemble carburetor magneto or engine unless it has been found to be the cause of malfunctioning the plug hole To avoid an electric shock do not hold the plug itself Make sure to hold the plug cap Engine hard to start Remove spark plug and NO gt Are spark produced when YES Faulty spark plug Replace check spark by cranking spark plug is replaced engine while having the VESI plug touched against NO engine block Y AWARNING Are sparks produced pate Faulty ignition coil Replace Keep the plug as far when ignition coil is
52. e dry AAWARNING Clean the crankcase and cover in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean parts A fire or explosion could result e Be sure to replace any oil seal removed with a new one O Install the oil seal so that the marks A face out O Pack some amount of a high temperature grease B into the space between the seal lip C and dust lip D Press in the new oil seal using a press or suitable tools until it is flush with flange surface E Do not damage the seal lips e When replacing the oil seal A of the governor shaft note the following O Install the oil seal into the crankcase cover B after the governor shaft is inserted in the cover and so that the marks C face out O The depth D is 0 2 mm 0 0 08 in e When installing the governor shaft and plate in the crankcase cover see Fuel System chapter 830P6050S1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 6 5 Crankcase e Check to see that the crankcase dowel pins A are in place on the crankcase e Install the gasket B on the crankcase e Install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence shown Torque Crankcase Cover B
53. e 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 Use soap warm water and clean rags Clean the cylinder wall for white glove inspection A clean white rag should not show soil from the cylinder wall e Dry the cylinder and coat with a engine oil CAUTION The cylinder must be thoroughly cleaned after honing to eliminate all grit www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 4 23 Muffler Muffler Removal e Remove the bolt B on the muffler bracket e Unscrew the flange nuts A and remove the muffler Use a penetrating oil if necessary to break threads loose e Do not use unnecessary force when removing the muffler assembly or they could become damaged or distored e Remove the gaskets Muffler Installation e Clean the muffler flanges to the exhaust port gasket surfaces and install a new gaskets each time the muffler installed e Install the gasket e Install the muffler e To prevent mis threading finger tight the flange nuts first Next tighten the nuts e Tighten the nuts Torque Muffler Flange Nuts 15 N m 1 5 kgf m 11 ft lb e After installation thoroughly warm up the engine wait until the engine cools down and retighten the bolts and nuts Inspection e Inspect the muffler for dents cracks rust and holes
54. e intake manifold B e Tighten the mounting bolts C Torque Intake Manifold Mounting Bolts 5 9 N m 0 6 kgf m 52 in Ib e Install and tighten the band A around the manifold B and wirelead C and or harness D O Position the wire and or harness on top of the manifold as shown e Cut excess the band off e Install the other removed parts www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 2 17 Intake Manifold Intake Manifold Inspection e Inspect the intake manifold for cracks or porous casting e Cracks not visible to the eye may be detected by 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 cracks is present the coating will become discolored at the defective area If a crack is present in the intake manifold replace it e Inspect the gasket surfaces for burns and nicks www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 18 FUEL SYSTEM Fuel Pump Fuel Filter The fuel pump cannot be disassembled if any damage for the pump is noticed replace it with a new one Fuel Pump Inspection e Check the vent hole A and filter B for plugging or clogging If vent hole and filter are plugged or clogged remove the foreign matter from them Fuel Flow Test WA TO Gasoline is ex
55. e trigger sensor TS1 senses the optimum time peak current to remove the base drive from the transistor Q1 This abrupt turning off of the transistor causes an interruption in current flow which allows its associated flux collapse and several hundred volts is induced through the primary winding L1 inducing a very large voltage in the secondary winding L2 When the secondary voltage reaches several thousand volts the spark plug SP gap is ionized and ignition occurs The placement of the trigger sensor internal to the ignition insures constant timing over speed and temperature and prevents counterclockwise operation The diode D1 in the ignition shut off circuit blocks inadvertent application of battery voltage protecting the internal components of the ignition With the stop switch SW in the closed position primary voltage is routed to ground preventing ignition operation www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 7 13 Charging Ignition System Ignition Coil Removal e Remove Fan Housing see Flywheel Stator Coil Removal Spark Plug Cap A Stop Switch Lead Connector B Bolts C Ignition Coil D Ignition Coil Installation e Install ignition coil on crankcase so that the stop switch lead connector B face the screen and tighten bolt 1 first then bolt 2 While tightening bolts adjust the ignition coil air gap A between the three legs of ignit
56. eaner and exhaust system TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED Federal law and California State law prohibits the following acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new engine for the purpose of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the engine after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Do not tamper with the original emission related part Carburetor and internal parts Spark plugs Magneto or electronic ignition system Fuel filter element Air cleaner elements Crankcase Cylinder heads Breather chamber and internal parts Intake 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 information to make it useful to the owner who desires to perform his own basic maintenance and 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 h
57. eat with a vacuum cap tool www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 14 ENGINE TOP END Valves e Coat the face of valve sparingly with a fine lapping compound e Use the vacuum cup tool A to grip top of the valve B Rotate the valve in a circular motion to lap the valve to the seat e Lift the valve slightly from the seat every 8 to 10 strokes continue lapping operation until a uniform ring appears around entire surface of the valve face 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 clear ances see Valve Clearance Adjustment Valve Head Thickness e Remove the valve see Valve Mechanism Removal Installation e Measure the thickness of the valve head If the valve head thickness valve margin A is less than the service limit replace the valve A Valve Head Thickness Service Limit IN EX 0 35 mm 0 014 in Ho AN www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 4 15 Valves Valve Stem Runout e Support the valve in V blocks at each end of the stem e Position a dial gauge perpendicular to the stem e Turn the valve and rea
58. eeaeesaeeseeeeeaeeeieeseeeeeaten 6 14 Crankshaft RUNO UT sch och esha eaetelen eta aia ieles oi avin des 6 15 Crankshaft Main Journal Weab ccscccecceesceesseceeesesceeeneeseeseaeneaeecseecsaeseaesensesaesaeneaaesaaeeaeesaeseaaeeeeeseeeseaeeneesneeteaees 6 15 Grankpin RESIZING ii cisne eta ca CS Sie ae ena ea Le is 6 15 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 2 CAMSHAFT CRANKSHAFT Exploded View 830P6012W4 C NF a ie 1 Other than FH721D Engine 2 FH721D Engine O Apply engine oil G Apply grease www mymowerparts com S Follow the specific tightening sequence SS Apply silicone sealant T3 9 8 N m 1 0 kgf m 87 in Ib T1 2 0 N m 0 2 kgf m 18 in lb T2 5 9 N m 0 6 kgf m 52 in lb T4 25 N m 2 6 kgf m 19 ft lb T5 44 N m 4 5 kgf m 33 ft lb For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 6 3 Specifications Service Limit Camshaft Tappet Cam lobe height Intake 29 621 mm 1 166 in Exhaust 29 621 mm 1 166 in Camshaft journal diameter PTO side 15 985 mm 0 6293 in Flywheel side 15 985 mm 0 6293 in Camshaft bearing inside diameter Crankcase 16 136 mm 0 6352 in Crankcase cover 16 136 mm 0 6352 in Crankshaft Connecting Rod Connecting rod bend Connecting rod twist Connecting rod big end width Crankpin width 0 15 100 mm 0 006 3 94 in 0 15 100 mm 0 006 3 94
59. elease Low idle speed Fast idle speed Ignition system RFI Starting system Charging system Spark plug Carburetor Fuel pump Air cleaner Governor Lubrication system Oil filter Oil pressuer switch Oil capacity Cooling system Dimensions L x W x H without muffler Dry weight without muffler FH601D FH641D FH680D FH721D Forced air cooled horizontal shaft OHV 4 stroke gasoline engine 90 V Twin 75 2 mm x 76 mm 2 96 in x 2 99 in 675 mL 41 19 cu in Counterclockwise facing the PTO shaft Automatic compression release 1550 rpm 3600 rpm Transistorized fly wheel magneto Per Canada and U S A requirements Electric starter 12 V 13 amps with regulator NGK BPR4ES Float type fixed main jet two barrel Diaphragm type pulse pump Dual stage element dry type Flyweight all speed governor Pressure feed by positive displacement pump Cartridge type full flow filter ON OFF switch 1 6 L 1 7 US qt when engine is completely dry Forced air cooling by fan 442 mm x 430 mm x 491 mm 17 4 in x 16 9 in x 19 3 in 44 5 kg 98 1 Ib Specifications subject to change without notice www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 1 6 GENERAL INFORMATION Periodic Maintenance Chart To ensure satisfactory operation over an extended period of time any engine requires normal maintenance regular intervals The Periodic Maintenance Chart below shows periodic inspection and maintenance items an
60. 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 Tool Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 57001 1097 e Insert the piston and connecting rod so that the arrow match mark A on the top of the piston is facing the flywheel side B CAUTION The connecting rod and the connecting rod big end cap are machined at the factory in the assembled state so they must be replaced together as a set e Apply engine oil to the inner surface A of the connecting rod big end B and caps C e Install the connecting rod big end caps on their original position on each connecting rod big ends e Apply a small amount of engine oil to the thread D and seating surface E of the cap bolts e Tighten the cap bolts Torque Connecting Rod Big End Cap Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install e Camshaft see Camshaft Crankshaft chapter e Crankcase Cover see Camshaft Crankshaft chapter Piston Cylinder Seizure e In case of seizure remove the piston e Visually inspect the cylinder and piston damage x If there is only light damage smooth the position with 400 emery cloth Remove the small aluminum deposits from the cylinder with 400 emery cloth or light honing x If the damage is
61. engine so the oil will drain easily Stop the engine e Place the engine on a level surface e Place a suitable container under the engine e Remove the drain plug A and drain the oil WARNING Be careful of hot oil when drained It may be hot enough to burn you severely e Check the O ring B at the drain plug for damage Replace the O ring with a new one if it is damaged If 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 Ib e Install the 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 20 N m 2 0 kgf m 14 5 ft lb www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 6 LUBRICATION SYSTEM Engine Oil Oil Filter and Oil Cooler e Remove the oil filler cap and pour in the specified type and amount of oil Engine Oil Grade API Service Classification SF SG SH or SJ Class Viscosity SAE40 SAE30 SAE10W 30 SAE10W 40 or SAE5W 20 Capacity 1 4 L 1 5 US qt When oil filter is not removed 1 6 L 1 7 US qt When oil filter is removed Level Between H and L marks on oil gauge NOTE O Some increase in oil consumption may be expected when a multi grade engine oil 10W 30 10W 40 5W 20 is used Check the oil level frequently Oil Filter Removal
62. er of turns needed to closed the screw Turn out the pilot screw to replace it with anew one Install the new pilot screw until the screw is gently seated Then open the screw the same number of turns as recorded prior to removal O Align the limiter with the mark on the carburetor body to install taking care not to turn the pilot screw e Install the choke valve and throttle valve on the shaft as the out side mark of them facing outside and apply a small amount of a bondng agent to the valve screw threads CAUTION Do not apply too much bonding aent to the valve screws itself may be fixed e Drive the float pin so that it s big diameter side faces the throttle shaft lever e The fuel inlet valve seat is pressed into the carburetor body and is not replaceable e Assemble carburetor parts which recommended tightening torque see Exploded View 1 Limiter 16 2 Pilot Screw 17 3 Spring 18 4 Screw 19 5 Choke Valve 20 6 Choke Shaft 21 7 Seal 22 8 Screw 23 9 Throttle Valve 24 10 Throttle Shaft 25 11 Collar 26 12 Seal 27 13 Float Valve 14 Pin 15 Float 830P201752 C Gasket Pilot Jet Pilot Jet Plug Main Jet Gasket Main Jet L Main Jet R Gasket Solenoid Valve Screws Spring Drain Screw www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 14 FUEL SYSTEM Carburetor Carburetor Cleaning AWARNING Clean
63. er these conditions there is very little air flow through the carburetor bore so little that it is not enough to draw fuel through the main system of the carburetor and atomize it Instead the fuel is drawn through the pilot system since the nearly closed throttle valve K causes high speed air flow past the pilot outlet and bypass holes even at low engine speed Fuel flow in the pilot system is metered by the pilot jet Air for better atomization is admitted via the pilot air jet in the mouth of the carburetor The fuel air mixture passes into the bore of the carburetor side stream of the throttle valve through the bypass holes and pilot outlet While the 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 Turning the pilot screw Idle mixture screw out Counterclockwise enrichens the mixture turning it in clockwise leans the mixture Main Fuel Flow Pilot Fuel Flow gt www mymowerparts com For Kawasak
64. ference 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 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 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 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 3 Before Servicing 15 Cotter Pin Replace any cotter pins that were
65. ft before installing the flywheel e Install the flywheel onto the crankshaft taper so that the woodruff key fits in the key way in the hub of the flywheel e Install the fan A so that two positioning bosses B fit around flywheel ignition magnet C e Install the plate D so that the bosses E of the fan fit in the holes of the plate with bolts F e Install the bracket A so that the notch B inserts into the slot C in the flywheel www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 8 ELECTRICAL SYSTEM Charging Ignition System e Fit the conical washer A onto the flywheel bolt B and tighten the flywheel bolt CAUTION Make sure the direction of conical washer A for flywheel bolt B Direction is as illustration Torque Flywheel Bolt 56 N m 5 7 kgf m 41 ft Ib C Bracket D Flywheel E Crankshaft e Install the fan housing A and tighten the bolts B C Torque Fan Housing Bolts B M8 6 9 N m 0 70 kgf m 61 in Ib Fan Housing Bolts C M6 5 9 N m 0 60 kgf m 52 in Ib e Install the screen A and tighten the screen bolts B Torque Screen Bolt 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 7 9 Charging Ignition System Charging System Operational Inspection e Check battery condition NOTE Al
66. gram s hour s liter s For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LIST OF ABBREVIATIONS 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 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 gasses The blow by gasses are led to a breather chamber through the crankcase and from there to the air cleaner Oil is separated from the gasses while passing through the inside of the breather chamber from the crankcase and then returned to the bottom of crankcase 2 Exhaust Emission Control System The exhaust emission control system applied to this engine consists of a carburetor and an ignition system having optimum ignition timing characteristics The carburetor has been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cl
67. he crankcase cover with a inside micrometer at several points x If the inside diameter is more than the service limit replace the crankcase cover Pump Shaft Bearing Inside Diameter Service Limit 11 072 mm 0 4359 in e Visually inspect the relief valve spring steel ball and valve seat in the crankcase cover x If any rough spots are found during above inspection wash the valve clean with a high flash point solvent and blow out any foreign particles that may be in the valve with compressed air AAWARNING 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 606 678 9623 or 606 561 4983 LUBRICATION SYSTEM 5 11 Oil Pump Relief Valve x If cleaning does not solve the problem replace the relief valve parts x If necessary put the ball in position and lightly tap the ball with a suitable tools to form a perfect seat e Measure free length A of the spring with a vernier caliper x l the free length of the spring is less than the service limit replace the spring Relief Valve Spring Free Length Service Limit 19 50 mm 0 77 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 12 LUBRICATION SYSTEM Oil Screen Oil Screen Removal e Re
68. he engine is shipped dry Preoil the engine to force all air from the internal oil passages and the oil filter e Fill fresh engine oil to the specified level see Oil Level Inspection e Run the engine at slow speed 2 minutes e Stop the engine and check the oil level Oil Level Inspection e Place the engine on a level surface and check the oil level e Clean area around oil gauge A before removing it e Remove the oil gauge and wipe it with a clean cloth e Insert the oil gauge into gauge hole B and let its plug firmly fit into the gauge hole then check the oil level e The oil level should be the operating range between H line and L line on the oil gauge If the oil level is near or below the L line remove the oil filler cap C and add enough engine oil to bring oil level to the H line CAUTION Do not fill above the H line Excess oil will cause a smoking condition O Use the same type and make of oil that is already in the engine NOTE O If 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 too high remove the excess oil by loosening the drain plug D Oil Change e Change the oil after first 8 hours of operation Thereafter change oil every 100 hours e Start and warm up the
69. head 2 Cylinder head gasket use only the proper gasket The use of a gasket of incorrect thickness will change the compression 3 Valve guides and piston rings rapid carbon accumulation in the combustion chamber may be caused by worn valve guides and or worn piston oil rings This may be indicated by white exhaust smoke If cylinder compression is lower than the MIN check the following 1 Gas leakage around the cylinder head replace the damaged gasket and check the cylinder head warp Condition of the valve seating Valve clearance Piston cylinder wear piston seizure Piston ring piston ring groove nan www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 4 7 Cylinder Head Cylinder Head Assembly Removal e Remove Air Cleaner see Fuel System chapter Fan Housing see Electrical System chpater Muffler see Muffler Exhaust Pipe Removal Carburetor see Fuel System chapter Intake Manifold see Fuel System chapter Spark Plug e Unscrew the rocker cover mounting bolts A and remove the cover B and gasket e When removing the 1 2 cylinder head set each cylinder at T D C A of power stroke in e Loosen the cylinder head bolts 1 4 turn in the sequence shown CAUTION If the above procedure is not followed the cylinder head may be warped during removal e Repeat the sequence until all bolts are removed and lift off the c
70. here is no UP or Down to the rails They can be installed either way GE160130S81 e Do not mix up the top and second rings e Install the second and top rings as shown The rings should turn freely in the grooves A Piston Head B Top Ring C Second Ring e Align the piston and rings with the piston ring end gap as shown A Arrow Match Marks B Top ring End Gap Upper Steel Rail End Gap C 30 45 D Second Ring End Gap Lower Steel Rail End Gap e Apply engine oil to the piston pins Assemble the pistons onto the connecting rods as follow No 1 cyl Piston align the arrow match mark on the piston head with opposite the raised letters K Mark on the connecting rod No 2 cyl piston align the arrow match mark on the piston head with K Mark on the connecting rod A No 1 Cyl Piston B No 2 Cyl Piston C Arrow Match Marks D K Mark E Opposite K Mark e When installing a piston pin snap ring compress it only enough to install it and no more Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the notch B in the edge of the piston pin hole CAUTION Do not reuse the snap rings as removal weakens and deforms them They could fall out and score the cylinder wall www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 18 ENGINE TOP END Cylinder Piston e Apply
71. i Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 2 9 Carburetor Fuel Shut Off Solenoid Valve Electric Starter Model To avoid after firing when stopping the engine a solenoid actuated fuel shut off solenoid valve A is installed in the carburetor bowl The valve shuts off the fuel supply to the valve seat B simultaneously when the switch key turned to the OFF position The valve opens automatically when the switch key is turned to the Run position Low Idle Speed Adjustment e Disconnect all possible external loads from the engine e Start the engine and warm it up thoroughly AWARNING Always keep your hands clear of the moving parts e Move the throttle lever on dash to the idle position and hold the throttle lever on the carburetor in closed position turn the governer arm clockwise all the way and adjust the low idle speed screw A until the engine idles at specified speed Idle Speed Carburetor idle rpm 1450 rpm e Release the throttle lever and adjust the low idle speed set screw B on the control plate to obtain the specified governed low idle speed Low Idle Speed Governed idle rpm 1550 rpm 830P211AS1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 10 FUEL SYSTEM Carburetor High Idle Speed Adjustment NOTE O High idle speed adjustment should be made after the idle speed adjustment is
72. icates 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 In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require specified tightening torque oil grease or a locking agent during assembly www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 1 General Information Table of Contents Before Servicing ie ais naive nate ace een aio 1 2 Model ldentificatloN seisnesid pipaa a ae a Sees arate tiene eects deat Eaa a SEE aden E EA 1 4 General Specifications arn a A a ee ede EEEN E 1 5 Periodic Maintenance Gattis a a T ea aa a a a a a aa ae npc aae a cabo a e a e oa 1 6 Torqueand Locking AJE htss ahenea pene dt dt 1 7 Special TOOS nnns e e ee ne aed aed eel a 1 9 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 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
73. ion coil and the two pole plates to the specified value Ignition Coil Air Gap Standard 0 2 0 4 mm 0 008 0 016 in Torque Ignition Coil Bolts 5 9 N m 0 6 kgf m 52 in Ib NOTE O Above procedure must be used to insure proper coil air gap is not too large A Thickness Gauge B Bolts www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 14 ELECTRICAL SYSTEM Charging Ignition System Ignition Coil Inspection e Remove the ignition coils see Ignition Coil Removal e Measure the primary winding resistance as follows O Set the hand tester to the R x 1 kQ range Special Tool Hand Tester 57001 1394 O Make the measurements shown in the table Ignition Coil Primary Winding Resistance EN MEN CAUTION Use only Tester 57001 1394 for this test A tester other than the Kawasaki Hand Tester may show different readings If a megger or a meter with a large capacity battery is used the ignition coil will be damaged e Measure the secondary winding resistance as follows O Set the hand tester to the x 1 kQ range O Connect the tester between the iron core A and plug cap terminal C Ignition Coil Secondary Winding Resistance 8 w 11k0 If the tester does not read as specified replace the coil Spark Plug Cleaning and Inspection e Carefully pull the plug cap from the spark plug and remove the spark plug If the plug is oily or has carbo
74. is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Inspect the carburetor body for damage Flange sealing surfaces should be smooth and free of burns and nicks Replace the gasket if necessary e Turn the throttle and choke shafts to check that the throttle and choke butterfly valves move smoothly x If the valves do not move smoothly replace the carburetor body and or throttle shaft and choke shaft assembly e Check the gasket on the carburetor body x If the gasket is not in good condition replace it e Check the other parts of the carburetor for wear or damage Replace the part if necessary e Clean and check the float level as follows CAUTION Do not push down on the float during float level checking www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 2 15 Carburetor e With the float A assembly installed onto the carburetor body B hold the carburetor upside down at eye level Gently support the float with a finger and bring it down slowly so that the float arm tab C just touches the float valve needle D The float lower surface E should be parallel with the carburetor body mating surfaces F If the float position is not correct replace it e Inspect the inlet needle valve for excessive wear or damage The tip should be smooth without any grooves scratches or tears The
75. issolved in wood alcohol If a cracks is present the coating will become discolored at the defective area e f a cracks is present in the cylinder head replace it e Inspect the mating surface for burrs and nicks e Clean and inspect the rocker arm where it touches the push rod and valve stem If the contact points A are worn or damaged replace the rocker arm AL www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 4 11 Valves Valve Clearance Inspection NOTE O Valve clearance must be checked when the engine is cold at room temperature e Remove the rocker cover see Cylinder Head Removal e Place the piston at top dead center TDC of the compression stroke turning the crankshaft clockwise facing the flywheel No 1 Cylinder O The left projection A on the flywheel is faced with the right leg B on the 1 ignition coil C as shown O Check the intake and exhaust valves are closed completely if not turn the flywheel one turn 360 clockwise and face the left projection with the right leg again No 2 Cylinder O The left projection A on the flywheel is faced with the right leg B on the 2 ignition coil C as shown Follow No 1 Cylinder alignment e Then check the valve clearance Using a thickness gauge A measure the valve clearance between the rocker arm B and the valve stem end x If the valve clearance is inc
76. move the crankcase cover see Camshaft Crankcase chapter e Unscrew the mounting bolts A and remove the spacers B and pipe C e Push D the oil screen with thumbs and remove it Oil Screen Installation e Clean the oil screen thoroughly whenever it is removed for any reason e Insert the oil screen A into slots B in the pipe C and install the pipe on the crankcase cover with the mounting bolts and spacers Torque Oil Screen Mounting Bolts 5 9 N m 0 60 kgf m 52 in Ib Cleaning and Inspection e Clean the oil screen with high flash point solvent and remove any particles stuck to it AWARNING 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 O While 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 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 6 1 Camshaft Crankshaft Table of Contents Exploded Mi Wicca iia eek on A ie ee ee i eel ee 6 2 opecificationStanidaa md lla ata 6 3 Cruise A A R Ta 6 4 Crankcase Cover Removal nuit a id 6 4 Crankcase Cover Installation nec taba 6 4 Inspection aiei
77. must seal well and permit only filtered air to reach the carburetor x If the housing is damaged it must be replaced e Check that no foreign material is obstructing the air passage www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 COOLING SYSTEM 3 1 Cooling System Table of Contents Exploded MW ii it 3 2 Cooling Emi e o o e e Lak 3 3 Cooling Fan Removal cuina A ele a ae E a eta 3 3 Cooling Fan Installation dial a dott eee ain as 3 3 Cooling Fan Inspection ab e ida ee e 3 3 Screen Clearance AdjUStMent cccccecsccesceeeseeeseeeeceeseceeseecseeseessaeesaaeeseeneaeesaeesaaessaesesaeeaeesaeeesaeeneeseeeeeaeeeeesneesenees 3 3 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 2 COOLING SYSTEM Exploded View T1 2 0 N m 0 2 kgf m 18 in Ib T2 5 9 N m 0 6 kgf m 52 in Ib T3 6 9 N m 0 7 kgf m 61 in Ib www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 COOLING SYSTEM 3 3 Cooling Fan Cooling Fan Removal e Refer to Flywheel Removal in Electrical System chapter Cooling Fan Installation e Refer to Flywheel Installation in Electrical System chapter Cooling Fan Inspection e Visually inspect the blades A in the cooling fan B x If they are any cracks warps or damaged replace the cooling fan If any mud or dust have stuck to the cooling fan clean it e Co
78. n built up on it clean the plug using a high flash point solvent and a wire brush or other suitable tool x If the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug or its equivalent A Insulator B Center Electrode C Plug Gap D Side Electrode Spark Plug Gap Inspection e Measure the gap with a wire type thickness gauge x If the gap is incorrect carefully bend the side electrode with a suitable tool to obtain the correct gap Spark Plug Gap Standard 0 75 mm 0 030 in RIZZO NE SSS N N Y NY Q Zo SSS CZ S 6P10012351 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 7 15 Starter System Starter Motor Removal e Remove the mounting bolts A and pull the starter motor B from the engine Starter Motor Installation e Clean the starter motor and engine mounting flanges to ensure good electrical contact and tighten the mounting bolts Torque Starter Motor Mounting Bolts 15 N m 1 5 kgf m 11 0 ft Ib Starter Motor Disassembly e Remove Through Bolts and Nuts A Brush Plate B York C Cap D e While the collar A is pushing remove the snap ring B e Remove Spring A Pinion Assembly B Washer C Bracket D Armature E www mymowerparts com For
79. ng side of the rocker arm B and move it to clear the push rod C e Remove the push rods and mark them so they can be installed in their original positions during assembly e Turn the crankcase up side down so that the tappets will fall away from the cam lobes e Pull the camshaft A out of the crankcase e Remove the tappets A and mark them so they can be installed in their original positions during assembly Camshaft Tappet Installation e Apply engine oil to the following Tappet Journal Camshaft Journal Cam Lobe Surface Camshaft Gear e Align the punch marks A on the crankshaft gear and camshaft gear e Install the washer B on the camshaft www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 6 11 Camshaft Tappet Camshaft Disassembly e Remove the governor assembly see Fuel System chapter e Remove Spring A O Do 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 O The governor plate A must move freely O While shaking the camshaft ACR weight B swings smoothly Camshaft Inspection e Check the camshaft gear A for pitting fatigue cracks burrs or an evidence of improper tooth contact Replace the shaft if necessary e Check the top of the cam lobes B fo
80. ngiand Inspection nade adh naive ded ia eee acetate 4 10 VIVES tipica 4 11 Valve Clearance Inspector ardido siii 4 11 Valve Glearance Adjustment ocios 4 11 Valve Seat Inspirada Ba 4 12 Valve Seat Repaltiz its cia Sel i A eine A iat 4 12 Valve Head Thickn Ss is ccsecok e we 4 14 ValVE SEM RUN iio 4 15 ValVe Stem Diameter viciado a 4 15 Valve Guide Inside Di meter ansci decai 4 15 Valve Spring Inspector dias lr td 4 15 Cylinder PISTON i oia Ad A iii 4 16 A OO 4 16 Piston Installation oi ota ee Ll ed ee ee ee ele 4 17 Piston GCylinder Seizure circa edn dedine dak ad 4 18 Riston CleaninO recta errada noia dd dar ride 4 19 Piston Ring and Ring Groove We a oia 4 19 Piston Ring ENG Gal citrato Ri aos 4 20 Piston Pin Piston Pin Hole and Connecting Rod Weabl cccsscccssseceesneceseneeeeeeeeeceeeesaeeeseaeeeseaeeeseneesesseesenneeeees 4 20 Piston Dia MO leia heals vie ee i en A A ne at 4 21 Gylinder Inside Diameters cece eevee scada aE aare TE Ea EIN a 4 21 Cylinder Boring and Honig nenies ei nienie aaa a 4 21 WITTE E EE OA a 4 23 Muffler Removal codi o da alin 4 23 Muffler Installation Asian 4 23 Inspector oe 4 23 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 2 ENGINE TOP END Exploded View 830P4002N4 C O Apply engine oil T1 6 9 N m 0 7 kgf m 61 in lb T2 9 8 N m 1 0 kgf m 87 in lb T3 28 N m 2 8 kgf m 21 ft lb www mymowe
81. nstall the rocker arm on the stud bolt and screw in the pivot and locknut on the stud bolt temporarily NOTE Correct installation must be performed when adjusting the valve clearance see Valve Clearance Adjustment Cleaning and Inspection e Scrape the carbon deposits from the head and exhaust port with a suitable tool A To avoid gouging use scrapers that are made of a material that will not cause damage e Clean the head in a bath of high flash point solvent and dry it with compressed air WARNING Clean the cylinder head 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 the cylinder head A fire or explosion could result e Lay a straightedge A across the mating surface of the head at several different points and measure warp by inserting a thickness gauge B between the straightedge and head x If warp exceeds the service limit repair the mating surface Replace the cylinder head if the mating surface is badly damaged Cylinder Head Warp Service Limit 0 05 mm 0 002 in e Check the cylinder head for cracks or other damage e Cracks not visible to the eye may be detected by coating the suspected area with mixture of 25 kerosene and 75 light engine oil e Wipe the area dry and immediately apply a coating of zinc oxide d
82. ntly than the recommended intervals WARNING Because of the danger of highly flammable liquids do not use gasoline or a low flash point solvent to clean the element e Remove the foam element and the paper element e Clean the foam element A in a bath of detergent and water and let the element air dry throughly before install it www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 20 FUEL SYSTEM Air Cleaner e Clean the paper element A by tapping it gently on a flat surface to remove dust If the element is very dirty replace it with a new one CAUTION Do not use compressed air to clean the paper element Do not oil the paper or foam element Cleaner Body Removal e Remove the elements see Element Removal e Remove the cleaner body mounting bolts A nuts B screws C and holder bracket D e Do not miss rubber seal E e Pull the breather tube A off the hole of the cleaner body B Cleaner Body Installation e Insert the breather tube A from the crankcase into the hole B of the cleaner body e Install the cleaner body on the intake pipe and bracket with mounting bolts nuts and screws Torque Cleaner Body Mounting Bolts and Nuts 5 9 N m 0 6 kgf m 52 in Ib Housing Cover and Body Inspection e Clean the housing with detergent and water and dry thoroughly e Check the housing for deformation or other damage The housing
83. numbers are stamped on ends of the main jets High Altitude Main Jet Main Jet No Altitude FH601D FH641D FH680D FH721D 0 1000 m 0 3000 ft L 92 R 95 108 L and R 1000 2000 m 3000 L 89 R 92 105 Land R 6000 ft 2000 m 6000 ft and higher L 86 R 89 102 Land R 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 main jet plugs C and take off the main jet plugs and gaskets e Make sure that L L or R R mark on the float chamber is shown the main jet position e Using a proper blade screw driver carefully replace the main jet D with a new one for altitude expected e Tighten the main jet to the specification see Carburetor Disassembly Assembly e Install the gasket and the main jet plug Torque Main Jet Plug 19 N m 1 9 kgf m 14 ft lb Fuel System Cleanliness Inspection AWARNING Gasoline is extremely flammable and can be explosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove the air cleaner see Cleaner Body Removal e Conne
84. o 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 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 l the AC voltage reading is less than the specification replace the stator Unregulated Stator Output MIN 26 VAC 3 000 rpm www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 10 ELECTRICAL SYSTEM Charging Ignition System Regulator Removal e Remove Stator Coil Lead Connector A Regulator Screw B Regulator C Regulator Installation e Install the regulator and tighten the screws Torque Regulator Screw 3 4 N m 0 35 kgf m 30 in Ib Regulator Resistance e Set the KAWASAKI Hand Tester selector switch to the R x 100 2 position e Connect the test leads to the points shown on the chart and read the resistance There are two 2 types of Regulator on FH engines as follows with out Charging Monitor Type 3 Blades O Resistance value may vary with individual meters www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 7 11 Charging Ignition System With Charging Monitor type If the resistance is not as specifi 5 Blades
85. oling fan is cleaned by washing in detergent and water CAUTION Do not clean the cooling fan in oil solvent It may be damage by oil solvent Screen Clearance Adjustment e Check clearance between screen A and fan housing B If clearance is less than 1 mm add proper number of spacer C between screen Q and bracket comp D to adjust clearance G 1 3 mm F Screws G Clearance 1 3 mm 830P3005W2 C 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 TOP END 4 1 Engine Top End Table of Contents Exploded VOW ticas td it diets 4 2 Specifications 4 400k A et AA Sa RE SG a A eniai 4 5 Gylinder Head ci ada load et rl ta edo rd cd nte 9 Li case decia aa 4 6 Compression Measurement ciao aii aes ates renee Aree eect ae ate eden dde ne iO 4 6 Cylinder Head Assembly Removal coccion id 4 7 Cylinder Head Assembly Installation ccecceecceeeeeseeeeeeeeeeeeaeeeeeceeseaeeeaeeseeseaeseaeesaeesaaeseaeeeaeesieeseeeeeaeesieeseaeenaeeeaeees 4 7 Push Rod Removals acc lie SA a adas 4 8 Push Rod InstallatiOn 0 ri sai 4 8 Push Rod INSpection 2 eiii einen aa agin elisha ded Ea red aariaa aaa 4 9 Valve Mechanism Removal Installation eccceesceesseeseneeeeeeeeeneeeeeaeeeseaeeeeeaeeeeeaeeeeeeeeeneeesseneesseeeseeeeeseeessaeeennaeeeed 4 9 Gleani
86. olts 25 N m 2 6 kgf m 19 0 ft Ib Do not turn one screw down completely before the others as it may cause the crankcase cover to warp Inspection e Measure the inside diameter A of the PTO shaft bearing on the crankcase cover at several points This bearing is not replaceable Replace the crankcase cover if the inside diameter is more than the service limit PTO Shaft Bearing Inside Diameter Service Limit 40 15 mm 1 581 in e Measure the inside diameter A of the crankshaft journal bearing on the crankcase at several points This bearing is not replaceable Replace the crankcase if the inside diameter is more than the service limit Crankshaft Journal Bearing Inside Diameter Service Limit 40 15 mm 1 581 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 6 CAMSHAFT CRANKSHAFT Crankcase Cleaning e Remove Camshaft and Tappets see Camshaft Tappet Removal Crankshaft see Crankshaft Removal e Clean up the crankcase and cover with a high flash point solvent and blow out any foreign particles that may be in the pockets inside of the crankcase with compressed air AWARNING Clean the crankcase and cover in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents www mymowerparts com For Kawasaki Discount Parts
87. on Coil Installation iv uote arde e dad a 7 13 Ignition Coil Inspection iaa dite ene di elie al ee es 7 14 Spark Plug Cleaning and INSPeCtION ec eeceeeeeeeeeeeeeeeeeeeaeeeeeeeseesaeeeaeeeeeseeeeeaeesaeeseeeeaeseaeeseeseaeseaeesaeesiaeseaeeeeeeaes 7 14 Spark Plug Gap Inspection inci pide 7 14 Sade SM iii 7 15 Starter Motor Removal cionado aid 7 15 Starter Motor Installation A ala tee 7 15 Starter Motor BIETE EEI o TEE SATA T ads 7 15 Startet Motor ASSEMbIY sssrin hisia i sa e ee S taona asian ee 7 16 Starter Motor Brush Inspection licor praia aiaa e ne a a e Aaaa AREE a eela EASE Peara EN EE Aa ciente 7 16 Brush Spring Inspection wiii iii liar leds 7 16 Armature INSpeCtion irae ee es a ee a EY 7 16 Yoke Assembly INSPECHON apan a ee a is 7 18 Pinion Glutch Inspection icussi il a api 7 18 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 2 ELECTRICAL SYSTEM Exploded View 830P7012W4 C G Apply grease SS Apply silicone sealant T1 3 4 N m 0 35 kgf m 30 in Ib T2 5 9 N m 0 6 kgf m 52 in Ib T3 9 8 N m 1 0 kgf m 87 in Ib T4 15 N m 1 5 kgf m 11 ft lb T5 19 N m 1 9 kgf m 14 ft lb T6 22 N m 2 2 kgf m 16 ft lb T7 56 N m 5 7 kgf m 41 ft lb www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 7 3 Specifications Charging System Regulated output voltage Alternator s
88. ore grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE Do 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 operate the cutter B with one hand C Do not apply too much force to the diamond portion NOTE Prior to grinding apply oil to the cutter and during the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash the cutter with washing oil and apply a thin layer of engine oil before storing www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 4 13 Valves Marks Stamped on the Cutter The marks stamped on the back of the cutter represent the following 1 Cutter number selected from 1 to 12 30 Cutter angle A 37 5 Outer diameter of cutter B KS8B Manufactured lot number Operating Procedures e Clean the seat area carefully e Recondition the valve seats with the valve seat cutters 45 30 and lap the valves e Check the seats for good contact all the way around with machinist s dye e Measure the seat width A If it is more than the STD width the seating surface should be refaced e l the valve seating pattern is not correct repair the seat e Coat the seat with machinis
89. orrect adjust it Valve Clearance when cold Intake Exhaust 0 1 0 15 mm 0 004 0 006 in Valve Clearance Adjustment e Since valve repairs change the valve clearance adjust the valve clearance to the specification e Assemble the cylinder head and install the cylinder head assembly on the block see Cylinder Head Installation e Turn the crankshaft proper direction until the piston is at TDC of the compression stroke described above e Loosen the lock screws A and valve clearance adjusting nuts B e Insert a 0 10 mm 0 004 in thickness gauge C between the rocker arm and valve stem and tighten the adjusting nut until the thickness gauge begin to bind between the rocker arm and valve stem end Use a sweeping motion with the thickness gauge while making this adjustment Valve Clearance when cold Intake Exhaust 0 1 0 15 mm 0 004 0 006 in e Holding the adjusting Nut with a spanner tighten the lock screw to the specified torque Torque Valve Clearance Lock Screws 6 9 N m 0 70 kgf m 61 in Ib e Do not overtighten e Remeasure any clearance that was adjusted Readjust if necessary www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 12 ENGINE TOP END Valves Valve Seat Inspection e Remove the valve see Valve Mechanism Removal Installation e Inspect the valve seats for damage x If the seats are warped or distorted beyond reconditioning replace A
90. overs see Cylinder Head Assembly Removal e Loosen the valve clearance adjusting nuts A e Move the rocker arms B to clear the push rod C upper ends e Pull out the push rods NOTE O Mark the push rods so they can be installed in their original position during assembly Push Rod Installation e Set each cylinder at T D C of power stroke e Install the push rods A in their original positions on each cylinder O To Install the push rod in a correct position on the tappet B insert the push rod so end of the push rod is sliding down C along inside wall D of the crankcase and position the push rod end on to the tappet e Check that both intake and exhaust push rods on each cylinder are at lowest position on the cam lobes E if not turn the flywheel clockwise one turn 360 and reset each cylinder at T D C of power stroke in 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 ENGINE TOP END 4 9 Cylinder Head Push Rod Inspection e Place the rocker arm push rod in V blocks that are as far apart as possible and set a dial gauge on the rod at a point halfway between the blocks Turn the rod to measure the runout The difference between highest and the lowest dial readings is the amount of runout
91. r wear burrs or uneven contact Replace the shaft if necessary Camshaft Bearing Journal Wear e Measure the height of each cam lobe If the cam height is less than the service limit for either lobe replace the camshaft Cam Lobe Height Service Limit 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 6 12 CAMSHAFT CRANKSHAFT Camshaft Tappet e Measure both camshaft journals at several points around the journal circumference If the journal diameter is less than the service limit replace the camshaft PTO Side Camshaft Journal Diameter Service Limit 15 985 mm 0 6293 in Flywheel Side Camshaft Journal Diameter Service Limit 15 985 mm 0 6293 in e Measure the inside diameter A of the camshaft bearing on the crankcase at several points This bearing is not replaceable Replace the crankcase if the inside diameter is more than the service limit Camshaft Bearing Inside Diameter Crankcase Service Limit 16 136 mm 0 6352 in e Measure the inside diameter A of the camshaft bearing on the crankcase cover at several points This bearing is not replaceable Replace the crankcase cover if the inside diameter is more than the service limit Camshaft Bearing Inside Diameter Crankcase Cover Service Limit 16 136 mm 0 6352 in www mymowerparts com For Kawasaki Discount Parts
92. ration O Measure coil and winding resistance when the part is cold at room temperature O Electrical Connectors Female Connectors A 6P06010151 Male Connectors B 6P06010251 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 6 ELECTRICAL SYSTEM Charging Ignition System Flywheel Stator Coil Removal e Remove Screws B and Screen A e Loosen the fan housing bolts A and remove the fan housing B e Remove Bolts A Ignition Coils B see Ignition Coil Removal e Hold the flywheel with a suitable tool C remove the flywheel bolt B washer and bracket A e Remove the bolts A plate B and fan C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 7 7 Charging Ignition System e Using a suitable flywheel puller A remove the flywheel B CAUTION Always use flywheel puller e Remove Woodruff Key A Screws B Stator Coil C 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 following portions and dry them with a clean cloth A Crankshaft Tapered Portion B Flywheel Tapered Portion e Fit the woodruff key C securely in the slot in the cranksha
93. re musts when servicing electrical systems Learn and observe all the rules below Do not reverse the battery lead connections This will burn out the diodes in the electrical parts O Always check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical system tests O The electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them To prevent damage to electrical parts do not disconnect the battery leads or any other electrical connections when the engine switch is on or while the engine is running O Because of the large amount of current never keep the engine switch turned to the start position when the starter motor will not turn over or the current may burn out the starter motor windings O Take care not to short the leads that the directly connected to the battery positive terminal to the chassis ground O Troubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was brought on by some other item or items they too must be repaired or replaced or the replacement part will soon fail again Make sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc Poor wires and bad connections will affect electrical system ope
94. rns and pieces of the base and head gasket e Anchor the cylinder block on the drill press table before honing e Align the center of the cylinder bore to the press center Set the press to operate from 200 to 250 rpm e Connect the drive shaft to the hone and set the stop on the drill press so the hone can only extend 20 to 25 mm 3 4 to 1 0 in above the top or below the bottom of the cylinder liner e Rotate the adjusting nut knob on the hone until the stones contact snugly against the cylinder wall at the narrowest point Do not Force e Turn the stone by hand If you cannot turn it the stone is too tight Loosen the hone until it can be turned by hand e Be sure that the cylinder and hone are centered and aligned with the drive shaft and drill spindle e Pour honing oil inside of the cylinder during the honing operation Start the drill press Move the hone up and down in the cylinder approximately 20 cycles per minute e Check the diameter of the cylinder bore regularly during honing using an inside micrometer CAUTION Stop the drill press before measuring and remove the hone from the cylinder NOTE The finish should not be smooth but have a 40 to 60 degree crosshatch pattern e Hone the cylinder until it is about 0 007 to 0 009 mm 0 0003 to 0 0004 in large to allow for shrinkage when the cylinder cools NOTE Do not use gasoline kerosene or commercial solvent to clean the cylinder bore Thes
95. rod at the other end of the needle should move smoothly when push in and released If either the needle or the seat is worn or damaged replace the float assembly and carburetor body as a set Good Bad 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 e Check the spring for weakened condition replace it if necessary Fuel Shut Off Solenoid Valve Test e Unscrew the fuel shut off valve and remove the valve e Connect a 12 VDC source to the solenoid as shown x If the actuate solenoid plunger Needle Valve does not pop in when the Test Voltage is applied replace it NOTE O If may be necessary to push the plunger slightly for the plunger to withdraw 830P0217S1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 16 FUEL SYSTEM Intake Manifold Intake Manifold Removal e Remove Air Cleaner see Cleaner Body Removal Fan Housing Carburetor see Carburetor Removal e Cut off the band A and harness and or wire lead are released from intake manifold e Remove the manifold mounting bolts B and the intake manifold C Intake Manifold Installation e Replace the intake manifold gasket with new ones e Clean the mating surfaces of the cylinders and intake manifolds and fit a new gaskets A direction as shown B 12mm e Install th
96. rparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 4 3 Exploded View SION NN Oz 830P4013W4 C G Apply grease S Follow the specific tightening sequence T1 2 0 N m 0 2 kgf m 18 in Ib T2 5 9 N m 0 6 kgf m 52 in Ib T3 6 9 N m 0 7 kgf m 61 in Ib T4 28 N m 2 8 kgf m 21 ft lb T5 22 N m 2 2 kgf m 16 ft lb T6 44 N m 4 5 kgf m 33 ft lb 1 FH721D Engine www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 4 ENGINE TOP END Exploded View Geng fae ef 830P4014W3 C T1 15 N m 1 5 kgf m 11 0 ftlb www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 4 5 Specifications Cylinder Head Cylinder compression MIN Cylinder head warp Valves Valve head thickness Valve stem runout Valve stem diameter Valve guide inside diameter Valve spring free length Rocker arm push rod rounout Cylinder Piston Piston diameter Piston ring groove clearance Piston ring thickness Piston ring end gap Piston pin outside diameter Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Top Second Top Second Top Second Oil Service Limit 390 kPa 57 psi MIN 0 05 mm 0 002 in 0 35 mm 0 014 in 0 05 mm 0 002 in 5 95 mm 0 0234 in 5 93 mm
97. rtion replace it if necessary e Visually inspect the back plate B for damage or rough contact surface replace it if necessary e Inspect the valve seating surface C The surface should be free of nicks or burrs 830P0609S1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 6 9 Breather Breather Valve Installation e Be sure the drain hole A on the breather chamber does not accumulate with slugs e Install the breather valve on the cam gear side of the crankcase see Camshaft Tappet Removal Torque Breather Valve Screws 2 0 N m 0 2 kgf m 18 in Ib e Install a new gasket so the silicone bead side faces the crankcase and the breather chamber cover and tighten the bolts Torque Breather Chamber Cover Bolts 5 9 N m 0 6 kgf m 52 in Ib www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 10 CAMSHAFT CRANKSHAFT Camshaft Tappet Camshaft Tappet Removal e Set the engine on a clean surface while parts are being removed e Drain the oil see Lubrication System chapter e Remove Muffler see Engine Top End chapter Throttle Control Panel see Fuel System chapter Carburetor see Fuel System chapter Intake Manifold see Fuel System chapter Crankcase Cover see Crankcase Cover Removal Rocker Covers A e Position the piston TDC at the end of the compression stroke e Push down A the spri
98. ssive engine load Adjust Engine overheating See engine loss power Faulty ignition coil Replace High fuel level in carb float Adjust chamber including overflow High idling R P M Adjust eChoke partially closed Open choke Excessively backed off carbu Adjust retor pilot screw Worn piston piston rings Stuck piston Worn cylinder bore Replace Clean or replace Bore or replace Insufficient cyl head tightness Retighten Faulty valve seat contact Lap Plunge up of valve Adjust valve clearance Wrong valve timing Adjust Broken valve spring Replace Stuck valve Clean or replace Plugged oil ring groove Clean High oil level Adjust Worn valve stems and valve guide Replace 0il leakage along governor shaft Replace Oil leakage from oil seal Replace Oil leakage from mounting surface Oil leakage from drain plug Clogged breather valve Drain back hole in breather chamber plugged lncorrect oil viscosity Replace gasket Retighten or replace gasket Clean Clean Correct Worn piston rings Stuck piston rings Worn cylinder bore Replace Clean or replace Bore or replace www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 6 TROUBLESHOOTING Starter Motor Troubleshooting Guide 1 Disconnect spark plug caps from the spark plugs 2 Turn engine switch to START position and check condition
99. t s dye e Fit a 45 cutter A to the holder and slide it into the valve guide O Resurface 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 cylinder head must be replaced Do not turn the cutter counterclockwise or drop it against the seat or it will be dulled e Use a 30 seat cutter A to narrow the seat width to the STD width O Turn the seat cutter one turn at a time while pressing down very lightly Check the seat width after each turn CAUTION The 30 cutter removes material very quickly Check the seat width frequently to prevent over grinding NOTE O Keep the seat width as closely as possible to the STD width e Make a light pass 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 O Apply a machinist s dye to the valve face insert the valve and snap it closed against the seat several times The valve surface should show good contact all the way around Be sure the valve seat is centered on the valve face The position of the valve in the seat is evident after lapping the valve If the seat does not make proper contact lap the valve into s
100. t pp Correct screw Carb not properly adjusted m Adjust O Carb flange leaking at gasket Tighten or replace Worn carb body and throttle shaft Replace www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 4 TROUBLESHOOTING Engine Troubleshooting Guide Problem in the governor gt Olncorrect governor linkage Correct system adjustment Faulty governor spring Replace Governor ass y malfunctioning H Check Engine malfunctions at high speed Is revolution fluctuation of YES gt Plugged air hole in tank cap Clean relatively large period produced Entry of dust and air into fuel E Clean when a load is applied filter or fuel pipe Engine malfunctions at low speed Remove spark plug and check WEAK gt Faulty plug insulation Replace spark by cranking engine while Fouled electrodes E Clean having the plug touched against STRONG gt Faulty ignition coil Replace engine block lncorrect air gap Correct AWARNING Keep the plug as far away as possible from the plug hole To avoid an electric shock do not hold the plug itself Make sure to hold the plug cap Y Is unusual smoke emitted out of muffler YES NO Y gt Overrich fuel in pilot system H Turn in pilot screw by a minor extent Directly and gradually open
101. t runout O Set the crankshaft in a flywheel alignment jig or on V blocks gauge O Set a dial gauge against both bearing journals O Turn the crankshaft slowly to measure the runout The difference between the highest and lowest dial gauge readings TIR is the amount of runout If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Service Limit 0 05 mm 0 002 in TIR Crankshaft Main Journal Wear e Measure both main journals at several points around the journal circumference If the journal diameter is less than the service limit replace the crankshaft with a new one PTO Side Crankshaft Journal Diameter A Service Limit 39 896 mm 1 571 in Flywheel Side Crankshaft Journal Diameter B Service Limit 39 896 mm 1 571 in Crankpin Resizing Crankpin can be resized to accept 39 5 mm 1 5551 in dia under A size connecting rod The crankpin should be reground if the crankpin is so much undersize and so much scored that a lapping operation will prove unsatisfactory Reground can be done by a reliable repair shop gt F e Before sending the crankshaft inspect the crankpin for cracks D If any cracks no matter how small are found the crankshaft must be rejected y e The final finishing dimensions should be shown in the table C Finishing Dimensional Specifications ae A 39 457 39 470 mm 1 5534 1 5539 in R 2 3 2 7 mm
102. tator and the armature shaft B If the resistance is less than infinite the armature is shorted Replace GP11060851 the starter motor Commutator to Shaft Resistance www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 18 ELECTRICAL SYSTEM Starter System e Test the armature winding for shorts O Place the armature on a growler A Hold a thin metal strip e g hack saw blade on top of the armature O Turn on the growler and rotate the armature one complete turn x If the metal strip vibrates the windings are internally shorted to each other and the starter motor must be replaced Yoke Assembly Inspection e Set the hand tester to the R x 1 kQ range and measure the resistance between the positive brush es A and brush plate B If the resistance is less than infinite the positive brush is shorted to ground Replace the brush plate assembly Positive Brush to Ground Resistance eo 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 22 the brush plate is faulty Replace the brush plate assembly Negative Brush to Ground Resistance Close to 0 2 Pinion Clutch Inspection e Turn the pinion gear by hand The pinion gear should turn clockwise freely If the pinion clutch does not operate as it should or if it makes nois
103. tator coil resistance Unregulated stator output Regulator resistance Standard 14 1 V DC in the text 28 4 V AC 3000 rpm in the text Service Limit 15 V DC 26V AC 3000 rpm Ignition System Ignition coil Primary winding resistance Secondary winding resistance Spark Plug Plug gap in the text 8 to 11 KQ CHAMPION RCJ8Y 1 0 mm 0 040 in Electric Starter System Starter motor Carbon brush length with spring boss Commutator groove depth approx Commutator diameter Commutator runout Special Tool Hand Tester 57001 1394 www mymowerparts com 12 7 mm 0 500 in 2 0 mm 0 078 in 31 7 mm 1 250 in 6 4 mm 0 250 in 0 9 mm 0 035 in 31 1 mm 1 225 in 0 4 mm 0 016 in For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 4 ELECTRICAL SYSTEM Wiring Diagram Note Portion surrounded by shows KHI procurement parts TIT TT T AA TIT LITA DAA AT Spark Plugs x Carburetor ot hs O faa faa SR a E 8 lt S l Y KEN ke ots Ss Si 2 Starter S l SL A POS Charging Voltage Coil Regulator TL r Option W pz Oil Pressure Switch W fh ro JA VA A Oil Lamp a 3 4 o Solenoid Switch O PA WAZ Battery A FH721D0384 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 7 5 Precautions There are a number of important precautions that a
104. ter of the piston pin with a micrometer at several points x If the outside diameter is less than service limit replace the piston pin Piston Pin Outside Diameter Service Limit 15 96 mm 0 628 in e Measure the inside diameter A of the piston pin hole at several points on both side Use a dial bore gauge x If the inside diameter is more than the service limit replace the piston Piston Pin Hole Inside Diameter Service Limit 16 08 mm 0 633 in e Measure the inside diameter A of the small end of the connecting rod at several points Use a dial bore gauge x If the inside diameter is more than the service limit replace the connecting rod Connecting Rod Small End Inside Diameter Service Limit 16 05 mm 0 632 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 4 21 Cylinder Piston Piston Diameter e Measure the outside diameter of the piston 12 5 mm 0 9 in up from the bottom of the piston at a right angle to the direction of the piston pin hole x If the measurement is less than the service limit replace the piston Piston Diameter Service Limit 74 99 mm 2 952 in 12 5 Cylinder Inside Diameter e Clean and measure the cylinder inside diameter O Use a dial bore gauge to measure front to back and side to side at the points shown figure If any of the cylinder bore measurements is greater than the service limit the cylinder must
105. th Wear e Measure the connecting rod big end width A with a micrometer or dial caliper If the measurement is less than the service limit replace the connecting rod Connecting Rod Big End Width Service Limit 20 45 mm 0 805 in e Measure the crankpin width A with a dial caliper x If the crankpin width is more than the service limit replace the crankshaft Crankpin Width Service Limit 43 10 mm 1 697 in Connecting Rod Big End Bearing Crankpin Wear e Apply a light film of oil on the thread of the cap bolts e Install the cap bolts and tighten the bolts to the specified torque see Piston Installation in Engine Top End chapter e Measure the inside diameter A of big end at several points with a telescoping gauge or inside micrometer x If the inside diameter is more than the service limit replace the connecting rod with a new one Connecting Rod Big End Inside Diameter Service Limit 40 044 mm 1 5765 in e Measure the crankpin outside diameter A O Use a micrometer to measure several points around the crankpin circumference x If the crankpin diameter is less than the service limit replace the crankshaft with a new one Crankpin Outside Diameter Service Limit 39 940 mm 1 5724 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 6 15 Crankshaft Connecting Rod Crankshaft Runout e Measure the crankshaf
106. tremely flammable and can be explosive 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 If fuel flow is none or little replace the fuel pump x Check for clogged or damaged tubes and fuel filter Replace the faulty parts Fuel Filter Inspection e Visually inspect the fuel filter A x If the filter is clear with no signs of dirt or other contamination it is OK and need not be replaced x If the filter is dark or looks dirty replace 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 2 19 Air Cleaner Element Removal e Remove the air cleaner cover nut A and the air cleaner cover B e Remove Foam Element A Paper Element B Element Installation e Install the element correctly on the air cleaner body e Be sure the paper element is in place in the air cleaner body e Be sure the foam element is in place on the paper element body Element Cleaning and Inspection NOTE O In dusty areas the elements should be cleaned more freque
107. ty engine switch Repair or replace Faulty solenoid switch Replace YES Faulty pinion or ring gear Incorrect starter alignment Faulty pinion return mechanism Can stop starter by engine switch OFF Repair or replace Correct Repair or replace www mymowerparts com
108. urn has its own comprehensive Table of Contents The Periodic Maintenance Chart is located in the General Information chapter The chart gives a time schedule for required maintenance operations If you want spark plug information for example 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 section 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 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 lt also precedes the text of a WARNING CAUTION or NOTE x Ind
109. ways check battery condition before condemning other parts of the charging system The battery must be fully charged in order to conduct accurate charging system tests e Warm up the engine to bring the components up to their normal operating temperatures e Measure regulated output voltage at various engine speeds O Connect 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 But they must stay within the specified range 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 or the alternator output is insufficient for the loads Regulated Output Voltage Battery Voltage to 15 VDC Stator Coil Resistance e Disconnect the connector A e Measure the stator coil resistance Electric Starter Model O Connect an ohmmeter between stator pins B Stator Coil Resistance Electric Starter Model 0 01 to 0 1 Q x If the meter does not read as specified replace the stator coil If the coil has normal resistance but the voltage inspection showed the alternator to be defective the flywheel magnets have probably weakened and the flywheel must be replaced e Check for continuity between each stator pin and ground There should be n
110. ylinder head assembly NOTE O Mark the push rods so they can be installed in their original position during assembly Cylinder Head Assembly Installation e Clean the mating surfaces of the cylinder heads and cylinder e Install the push rods in their original positions on each cylinder see Push Rod Installation e Install the knock pins e Set each cylinder at T D C A of power stroke in e Puta new gaskets and the cylinder head assemblies on each cylinder then let the cylinder heads with push rods aligned under the rocker arms NOTE O As the head gaskets are coated with sealing agents be careful not to damage the surfaces www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 8 ENGINE TOP END Cylinder Head e Tighten the cylinder head bolts following the tightening sequence Torque Cylinder Head Bolts 25 N m 2 6 kgf m 19 0 ft Ib 1 CYLINDER 2 CYLINDER CAUTION A torque wrench must be used to assure proper torque Improper tightening of the head bolts can result in warping of the cylinder head e Check and adjust the valve clearance see Valve Clearance Inspec tion Valve Clearance Adjustment e Install the gasket and rocker cover Torque Rocker Cover Mounting Bolts 6 9 N m 0 70 kgf m 61 in Ib e Install the other removed parts Push Rod Removal e Set each cylinder at T D C of power stroke e Remove the rocker c

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