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4-Stroke Air-Cooled V-Twin Gasoline Engine Service Manual

1. 3 10 Governor Assembly Installation 3 11 Governor Assembly Inspection tnnt senten etn ndn 3 11 Governor SHAM Removal ade 3 11 Governor Shaft Installation 3 11 ATED TON tM ge 3 12 Fuel and Air FOW 3 12 Fuel Shut Off Solenoid Valve one etc iie Hine rud ba ER a 3 14 Low Idle Speed Adjustment ace rro re tita ha ee Vno 3 14 High Idle Speed Adjustment ce ente 3 14 High Al tude out eit ater ree 3 14 Main Jet Replacement scie eee e De dee e te ber teed 3 14 Fuel System Cleanliness InSpectlonts ooo ioni epe toto beet aped 3 15 Inlet pipe Removal donee ei eR dcos 3 16 Pipe mue LEE 3 16 Carburetor Hemoval pp 3 17 Carburetor EE ee un aa edente 3 18 Carburetor Disassembhv Assembhy sssssnneessnnrssertrrteennnrssrtrrsstrnretrnnttstntnsseennnnennnnnennne 3 19 Carburetor Clearing u uu ie 3 20 Carburetor rte se Festo dd 3 21 Fuel Shut Off Solenoid Valve Test pp 3 22 Imlet Ma nifeld CU ER 3 23 Inlet Manifold Removal pe
2. Rp eo cu p abes ee 7 7 Crankcase Cover Installation de metre er mere tet t EE 7 7 Crankcase Cover Inspection pp 7 8 Disassembly nace name 7 8 Grankcase Assembly ie de 7 8 Crankcase Inspection EE 7 9 Crankcase and Crankcase Cover 7 9 sic fectum 7 10 Breather Valve Removal reote ci e d 7 12 Breather Valve Installation EE 7 12 Breather valve inspectio u n oe 7 13 Breather Pipe Removal g u ei bei 7 13 Breather Pipe Installation tet e e htt I a 7 13 Camshaft TEE RR Ce 7 14 Camshaft Tappet Removal eet I ete 7 14 Camshaft Tappet aiite er m Edo de e 7 14 Camshaft Disassemibly 7 14 7 15 Camshaft Inspection pp 7 15 Camshaft Bearing Journal 7 15 Crankshaft Connecting Rod pp 7 17 Connecting Rod ane EE 7 17 Connecting Rod Installation d te ent uie i a UAM 7 17 Crankshaft Removal taceo o d edat otro Qoia See ae 7 17 Crankshaft EE e EE 7 17 Cleaning Inspectlgom 7 17 Connecting Bengd TWiSst eredi pepe po eres euren 7 18 Connecting Rod Big End Cra
3. 8 11 Recoil Starter 8 12 8 2 STARTER SYSTEM Exploded View Electric Starter Model KL050068N5 C STARTER SYSTEM 8 3 Exploded View Torque No Fastener Remarks N m kgf m ft Ib 1 Starter Motor Mounting Bolts 19 6 2 0 14 2 Starter Motor Through Bolts 3 95 0 40 35 in lb G Apply grease 8 4 STARTER SYSTEM Exploded View Recoil Starter Model STARTER SYSTEM 8 5 Exploded View No Fastener Remarks N m kgf m ft Ib 1 Fan Housing Stud Bolts 5 9 0 60 52 ml 2 Recoil Starter Mounting Bolts 5 9 0 60 52 ml 3 Starter Retainer Screw 5 9 0 60 52 L G Apply grease R Replacement Parts 8 6 STARTER SYSTEM Specifications Item Standard Service Limit Electric Starter System Starter Motor Carbon Brush Lengh FS Models 10 16 mm 0 4 in Commutator Groove Depth FS Models 1 27 mm 0 05 in Commutator Diameter FS Models 31 369 mm 1 235 in Commutator Runout FS Models 0 043 mm 0 0017 in STARTER SYSTEM 8 7 Electric Starter System Starter Motor Removal e Disconnect the wire e Remove the mounting bolts A and pull the starter motor B from the engine with the switch lead attached Starter Motor Installation e Clean the starter motor and engine mounting flanges to ensure good electrical contact
4. MM MuQ 5 14 Valve Clearance Inspection EE 5 14 Valve Clearance Adjustmentl CER Ts 5 14 Valve Seat Inspection oa tpa e ei Ee ptg oen 5 14 Valve Seal E PEE 5 14 Valve Head WR e en 5 14 Valve Stem Pupu 5 14 Valve Stem Diameter eios eese pel Pest lare en Resa tnus qe 5 14 Valve Guide Inside Diameter inn dede deve 5 15 Valve Spring Inspection o uu u ones hot ac ae uen 5 15 vilis muc 5 16 Piston RemoVal meet oci tla 5 16 FiStoriIristalldlio is e u SS es 5 17 Piston Gy linder Seizure cocci sudo aides au tata sedo Neca 5 19 Piston Cleaning pp 5 19 Piston Ring and Ring Groove Weal pp 5 20 cce Mme LA MM A 5 21 Piston Pin Piston Pin Hole and Connecting Rod 5 21 Piston DIETAT m a y pan a L pa ee 5 22 Cylinder Inside Diameter uenit tertie Rica e PH 5 22 5 2 ENGINE TOP END Exploded View KE020388W5 de gae C baci 9 Yo ENGINE TOP END 5 3 Exploded View No
5. eCheck and adjust valve clearance e Clean and lap valve seating surface Clean combustion chambers 1 Service more frequently under dusty conditions e 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 PERIODIC MAINTENANCE 2 3 Torque and Locking Agent The following tables list the tightening torque for the major fasteners and the parts requiring use of a non permanent locking agent or liquid gasket Letters used in the Remarks column mean EO Apply oil to the threads L Apply a non permanent locking agent to the threads R Replacement Parts S Tighten the fasteners following the specified sequence Torque Fastener Nm ft Ib Remarks Fuel System Control Panel and Inlet Pipe Mounting Nuts 5 9 0 60 52 mb Control Panel Mounting Bolt 5 9 0 60 52 in lb Governor Arm Clamp Nut 7 8 0 80 69 Governor Shaft Plate Screws 2 0 0 20 18 in lb Inlet Manifold Bolts 5 9 0 60 52 in lb S Main Jet 2 3 0 23 20 Throttle Valve Screws 0 68 0 069 6 0 in Ib L Electric Starter Model Solenoid Valve 4 5 0 46 40 Recoil Starter Model Float Chamber Mounting Screw 4 5 0 46 40 in Ib Cooling System Engine Shroud Bolts 78 Fan Housing Bolts 78 Electric Starter Model Cooling Fan Mounting Bolts 52 mb Cooling Fan Screen Screws 27 in lb Recoil Starter Model
6. CAMSHAFT CRANKSHAFT 7 11 Breather Recoil Starter Model IC wt OT mm H L 3 Geh 3 zr cu kyj a mm gt Fresh Air lt Blow by Gas 608036 4 C 7 12 CAMSHAFT CRANKSHAFT Breather Breather Valve Removal e Remove the stator coil see Flywheel and Stator Coil Re moval in the Electrical System chapter Cut off the band A e Remove Bolts B Breather Chamber Cover C Electric Starter Model D Recoil Starter Model E e Remove Breather Pipe A see Breather Pipe Removal Screw B Back Plate C Reed Valve D Breather Valve Installation e Align center of the valve seat with center of the reed valve and back plate e Tighten Torque Breather Valve Mounting Screws 2 0 0 20 kgf m 18 in Ib e Be sure the drain hole A on the breather chamber does not accumulate with slugs Electric Starter Model e Replace the breather chamber cover gasket with a new one e Install Breather Pipe see Breather Pipe Installation Gasket Breather Chamber Cover A e Tighten Torque Breather Chamber Cover Bolts B 5 9 0 60 kgf m 52 in Ib e Attach the stop switch lead C and solenoid valve con nector lead D to the breather chamber cover with the band E e Install the removed parts see appropriate chapters CAMSHAFT CRANKSHAFT 7 13 Breather Recoil Starter Model e Replace the breather chamber
7. UD 9 6 iem 9 7 Wiring Dagrami ua ree dette ctetu e sud 9 8 diee 9 10 medal ecu exces 9 11 Flywheel and Stator Coil Removal esses enne nennen nnne 9 11 Flywheel and Stator Coil Installation r 9 14 Charging System Operational Inspection pp 9 17 Stator Coil Resistance tns Dee cathe den ben iatis ie Ee 9 17 Unregulated Stator 9 18 Regulator Removal Ne 9 18 Reg lator STAN AL OM Eege 9 18 Regulator seca obe aes bl role e teria c 9 19 IGNITION 9 20 anion OM u uu Bando cece ene cb eie D redu s 9 21 Ignition Coil Installation irme rnt ep tende ete nut pecu e ie D euin a rne 9 22 Ignition oll InSpectlOll a e reete etin Dee de Ud pee da 9 23 Spark Plug Removal u uu uu asa 9 23 Spark PUG Stal AMON raso Spread 9 23 Spark Plug Cleaning and 9 23 Spark Plug Gap Inspections 9 20 meno v t edi 9 23 9 2 ELECTRICAL SYSTEM Exploded View Electric Star
8. Valve Spring Inspection e Inspect the valve spring for pitting cracks rusting and burns Replace the spring with a new one if necessary e Measure the free length A of the spring xIf the measurement is less than the service limit replace the spring with a new one Valve Spring Free Length Service Limit Inlet Exhaust 31 0 mm 1 22 in 6206060351 5 16 ENGINE TOP END Cylinder Piston Piston Removal e Remove Cylinder Head Assembly see Cylinder Head Assembly Removal Crankcase Cover see Crankcase Cover Removal in the Camshaft Crankshaft chapter Camshaft see Camshaft Tappet Removal in the Camshaft Crankshaft chapter e Turn the crankshaft to expose the connecting rod cap bolts A e Remove the bolts and take off the connecting rod caps B NOTE ONote the positions of the connecting rod caps for rein stalling the caps e Scrape the carbon depsits from the cylinder head with a suitable tool before the piston and connecting rod are pulled out e Push the connecting rod end into the cylinder and pull the piston and connecting rod out of the cylinder CAUTION Note the location of the arrow match mark A on the piston head in relation to Mark B on the connecting rod No 1 cylinder Mark on the connecting rod is face to face with No 2 cylinder Mark on con necting rod Keep parts together as a set e Remove one of the piston pin snap
9. ELECTRICAL SYSTEM 9 19 Charging System Regulator Resistance Electric Starter Model e Remove the regulator see Regulator Removal e Set the KAWASAKI Hand Tester selector switch to the R x 100 O position e Connect the test leads to the points shown on the chart and read the resistance Without Charging Monitor Type 3 Blades KH07058BS1 B C D A oo oo oo B L 0 0 D over than over than over than 1 MO 1 MO 1 NOTE OResistance value may vary with individual meters the resistance is not as specified replace the regulator with a new one 9 20 ELECTRICAL SYSTEM Ignition System This engine ignition is controlled by a solid state ignition assembly and requires no periodic main tenance except for the spark plugs The system consists of the following Inductive Ignition Assemblies Permanent Magnet Flywheel Spark Plugs Stop Switch 01 SW KH080558W2 C Co Core Lamination C Collector F Flywheel D1 Diode E Emitter M Magnet L1 Primary Coil R1 Control Resistor N North Pole L2 Secondary Coil TS1 Trigger Sensor S South Pole Q1 Transistor SP Spark Plug B Base SW Stop Switch Ignition System Operation Theory Permanent magnets are mounted around the edge area of a flywheel As the flywheel magnetic pole rotates clockwise and passes the ignition module on a laminated core group voltage is produce
10. If the gasket is not in good condition replace it with a new one e Check the other parts of the carburetor for any wear or damage Replace the part with a new one if necessary e Clean and check the float level as follows CAUTION Do not push down on the float during float level checking e With the float A assembly installed onto the carburetor body hold the carburetor upside down at eye level Gen tly support the float with a finger and bring it down slowly so that the float arm tab B just touches the float valve C The float lower surface D should be parallel with the carburetor body mating surfaces E xIf the float position is not correct replace the float with a new one Electric Starter Model F Recoil Starter Model G 05201851 C 5202851 3 22 FUEL SYSTEM Carburetor e Inspect the float valve for excessive wear or damage The tip should be smooth without any grooves scratches or tears The rod at the other end of the needle should move smoothly when push in and released Good A Not Good B If either the needle or the seat is worn or damaged re place the float assembly and carburetor body as a set with a new one e Inspect the tapered portion A of the pilot screw B for wear or damage the pilot screw is worn or damaged on the tapered por tion replace it with a new one e Check the spring for weakened condition replace it with a new one if
11. 7571033ST Engine Oil and Oil Filter CAUTION Engine operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure and accident Engine Oil Level Inspection e Refer to the Engine Oil Level Inspection in the Periodic Maintenance chapter Engine Oil Change e Refer to the Engine Oil Change in the Periodic Mainte nance chapter Oil Filter Removal e Refer to the Oil Filter Replacement in the Periodic Main tenance chapter Oil Filter Installation e Refer to the Oil Filter Replacement in the Periodic Main tenance chapter LUBRICATION SYSTEM 6 7 6 8 LUBRICATION SYSTEM Pressurized Lubrication System The engine lubrication circuit is a pressurized system consisting of a positive displacement pump which picks up oil through a filter screen from the crankcase The oil is pumped to a replaceable oil filter cartridge through the engine s oil passages to lubricate internal components and return to the crankcase A pressure relief valve is used between the oil pump and oil filter to relleve excessive oil pressure by returning excess oil to the crankcase see Oil Flow Chart Oil Pressure Measurement e Remove the oil passage plug A from the crankcase e Install the oil pressure gauge adapter A and oil pressure gauge B Special Tools Oil Pressure Gauge 10 kgf cm 57001 164 Oil Pressure Gauge Adapter PT 1 8 57001 1033 e Run the
12. FS541V Kawasaki FS600V 4 Stroke Air Cooled V Twin Gasoline Engine Service Manual Quick Reference Guide General Information Periodic Maintenance Fuel System Cooling System Engine Top End Lubrication System Camshaft Crankshaft Starter System Electrical System e Troubleshooting This quick reference guide will assist you in locating a desired topic or pro cedure the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the spe cific topic required FS481V FS541V FS600V Kawasaki 4 Stroke Air Cooled V Twin Gasoline Engine Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Division Consumer Products amp Machinery Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured pre
13. e Install Gasket Inlet Pipe B Ground Lead C e Tighten Torque Carburetor and Inlet Pipe Mounting Nut D 5 9 N m 0 60 kgf m 52 in lb e Connect the breather hose A so that the clamp knob B faces the downward e Install the removed parts see appropriate chapters Recoil Starter Model e Replace the gasket A with a new one e Install Gasket Inlet Pipe B e Tighten Torque Carburetor and Inlet Pipe Mounting Nut C 5 9 0 60 kgf m 52 in Ib KC05197BS1 KC05211BS1 Carburetor e Connect the breather hose A so that the clamp knob B faces the downward e Install the removed parts see appropriate chapters Carburetor Removal WARNING Gasoline is extremely flammable and can plosive under certain conditions Turn the engine switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove the inlet pipe see Inlet Pipe Removal e Close the fuel shut off valve in the equipment e Remove the clamp A e Disconnect Fuel Tube B Solenoid Valve Connector C Electric Starter Model only Electric Starter Model D Recoil Starter Model E e Unhook the throttle link spring A at the throttle shaft lever top end B with a long nose plier while pull off the carbu retor e Unhook the throttle link rod C from the top end of the th
14. e Install the removed parts see appropriate chapter Charging System Charging System Operational Inspection Electric Starter Model e Check the battery condition NOTE OAlways check the battery condition before judging other parts of the charging system The battery must be fully charged for accurate charging system tests e Warm up the engine to bring the components up to their normal operating temperatures e Measure regulated output voltage at various engine speeds OConnect a voltmeter across the battery terminals The readings should show nearly battery voltage when the engine speed is low and as the engine speed rises the readings should also rise 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 the output voltage does 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 V DC Stator Coil Resistance e Disconnect the stator coil lead connector A e Measure the stator coil resistance Electric Starter Model OConnect a hand tester between stator pins B Special Tool Hand Tester 57001 1394 Stator Coil Resistance 0 1 0 14 O Measure the stator coil resistance Recoil Starter Model OConnect a hand tester between the stator coil lead con nector
15. e Remove the valve see Valve Mechanism Removal Instal lation e Measure the valve head thickness If the valve head thickness valve margin A is less than the service limit replace the valve with a new one Valve Head Thickness Service Limit Inlet Exhaust 0 35 mm 0 0138 in Valve Stem Runout e Support the valve on V blocks at each end of the stem e Position a dial gauge perpendicular to the stem e Turn the valve and read the variation on the dial gauge x If the stem runout is greater than service limit replace the valve Valve Stem Runout Service Limit Inlet Exhaust TIR 0 05 mm 0 002 in Valve Stem Diameter e Measure the diameter of the valve stem A in two di rections at right angles at four different positions on the stem lf any single measurement is less than the service limit replace the valve with a new one Valve Stem Diameter Service Limit Inlet 5 95 mm 0 234 in Exhaust 5 93 mm 0 233 in KE05007BS1 C e GE03010781 KE05008BS1 ENGINE TOP END 5 15 Valves Valve Guide Inside Diameter e Use a small bore gauge or a micrometer to measure the inside diameter A of the valve guide B at three positions down the guide length the measurement is more than the service limit replace the cylinder head with a new one Valve Guide Inside Diameter Service Limit Inlet Exhaust 6 08 mm 0 239 in
16. long and insert the arbor through the connecting rod small end OOn surface plate set the big end arbor on V blocks OWith the connecting rod held vertically use a height gauge to measure the height difference of the small end arbor on the surface plate Using a dial gauge measure the height at two different positions and the distance of the two positions is 100 mm 3 94 in B Then deter mine the connecting rod bent from the measured height differences C connecting rod bend exceeds the service limit replace the connecting rod with a new one Connecting Rod Bend Service Limit TIR 0 15 100 mm 0 006 3 94 in e Measure the connecting rod twist OWith the big end arbor still on the V blocks hold the con nection rod horizontally and measure the amount that the small end arbor difference Using a dial gauge measure the height at tow different positions and the distance of the two positions is 100 mm 3 94 in A Then deter mine the connecting rod twist from the measured height differences B If connection rod twist exceeds the service limit replace the connecting rod with a new one Connecting Rod Twist Service Limit TIR 0 15 100 mm 0 006 3 94 in Connecting Rod Big End Crankpin Width Wear e Measure the connecting rod big end width A with a mi crometer or a dial caliper the measurement is less than the service limit replace the connecting rod with a new one Connecting Rod Big End W
17. A and engine body Special Tool Head Tester 57001 1394 Stator Coil Resistance 4 4 15 Q ELECTRICAL SYSTEM 9 17 9 18 ELECTRICAL SYSTEM Charging System the measured value is not within the specification re place the stator coil with a new one If the coil has normal resistance but the voltage inspec tion shows the alternator to be defective the flywheel magnets have probably weakened and the flywheel must be replaced e Check for continuity between each stator pin and ground There should be no continuity infinite ohm the stator coil fails any of these tests replace the coil with a new one Unregulated Stator Output Electric Starter Model e Disconnect the stator coil lead 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 V 000 rpm the AC voltage reading is less than the specification replace the stator with a new one Unregulated Stator Output MIN 26 V AC 3 000 rpm Regulator Removal Electric Starter Model e Remove Stator Coil Lead Connector A Regulator Mounting Screws B Ground Lead C Regulator D Regulator Installation Electric Starter Model e Install Regulator A Ground Lead B e Tighten the regulator mounting screws C Apply dielectric grease to the regulator terminals D e Connect the stator coil lead connector E
18. Cooling Fan Plate Mounting Bolts 52 in lb Flywheel Bolts 41 Engine Top End Connecting Rod Big End Cap Bolts 9 8 1 0 87 in lb EO Cylinder Head Bolts 50 mm 27 4 2 8 20 S Cylinder Head Bolts 70 mm 27 4 2 8 20 S Lift Hook Bolt 5 9 0 60 52 in lb Rocker Arm Bracket Bolts 14 7 1 5 11 L Rocker Cover Bolts 5 9 0 60 52 in lb Spark Plugs 22 2 2 16 Valve Clearance Adjusting Locknuts 11 1 1 97 in lb Lubrication System Engine Oil Drain Plug 6 9 0 70 61 in lb Oil Filler Mounting Bolt 8 8 0 90 78 in lb Oil Filter 11 8 1 2 104 in Ib R Oil Pump Cover Plate Bolts 5 9 0 60 52 in lb Camshaft Crankshaft Breather Chamber Cover Bolts 5 9 0 60 52 in lb 2 4 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Breather Valve Mounting Screw Connecting Rod Big End Cap Bolts Crankcase Cover Bolts Crankcase Cover Oil Passage Plugs Crankcase Oil Passage Plugs Starter System Electric Starter Model Starter Motor Mounting Bolts 19 6 2 0 14 Starter Motor Through Bolts 3 95 0 40 35 Recoil Starter Model Fan Housing Stud Bolts 5 9 0 60 52 in lb Recoil Starter Mounting Bolts 5 9 0 60 52 in lb Recoil Starter Retainer Screw 5 9 0 60 52 in lb L Electrical System Flywheel Bolt 56 5 7 41 Ignition Coil Bolts 5 9 0 60 52 in lb Spark Plugs 22 2 2 16 Stator Coil Screws 3 4 0 35 30 in lb Recoil Starter Model Ignition Coil Stud Bolts 5 9 0 60 52 in lb The table below relating tightening torque to thread diameter lis
19. Fastener 101906 Remarks kgf m ft Ib 1 Connecting Rod Big End Cap Bolts 9 8 1 0 87 mb EO 2 Cylinder Head Bolts L 50 mm 27 4 2 8 20 S Head Bolts L 70 mm 27 4 2 8 20 S 4 Lift Hook Bolt 5 9 0 60 52 in lb 5 Arm Bracket Bolts 14 7 1 5 11 L 6 Rocker Cover Bolts 5 9 0 60 52 S 7 Spark Plugs 22 2 2 16 8 Valve Clearance Adjusting Locknuts 11 1 1 97 mb EO Apply engine oil L Apply a non parmanent locking agent MO Apply molybdenum disulfide oil R Replacement Parts S Tighten the fasteners following the specified sequence 5 4 ENGINE TOP END Specifications Item Cylinder Head Cylinder Compression MIN Cylinder Head Warp Service Limit 448 kPa 64 psi Engine Oil Temperature 50 60 122 1449 Cranking Speed 500 5 Seconds 0 05 mm 0 002 in Valves Valve Head Thickness Inlet Exhaust Valve Stem Runout Inlet Exhaust Valve Stem Diameter Inlet Exhaust Valve Guide Inside Diameter Inlet Exhaust Valve Spring Free Length Inlet Exhaust Rocker Arm Push Rod Runout Inlet Exhaust Rocker Shaft Outside Diameter Inlet Exhaust Rocker Arm Inside Diameter Inlet Exhaust Cylinder Piston Piston Diameter Piston Ring Groove Clearance Top Second Piston Ring Thickness Top Second Piston Ring End Gap Top Second Oil Piston Pin Outside Diameter Piston Pin Hole Inside Diameter Connecting Rod Small End Inside Dia
20. High Idle Speed Adjustment NOTE OHigh idle speed adjustment should be made after the idle speed adjustment is performed CAUTION Do not adjust high idle speed with the air cleaner removed e Start and warm up the engine thoroughly PERIODIC MAINTENANCE 2 7 2 8 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING Always keep your hands clear of the moving parts e Loosen the locknut A and unscrew the high idle set screw B few turns e Move the throttle lever on dash to obtain the specified high idle speed and leave it there High Idle Speed 3 600 r min rpm e Turn the high idle set screw so that the end of it just touches the speed control lever C and tighten the lock nut e Check the idle speed and readjust the idle speed if nec essary CAUTION Be sure to make the idle and fast idle speeds re spectively correspond to those of the equipment Fuel System Cleanliness Inspection WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the engine switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Electric Starter Model e Place a suitable container under the carburetor e Remove Solenoid Valve Connector A Solenoid Valve B Float Chamber C and Gasket e Check if water or dirt has
21. SAE40 SAE30 SAE10W 30 SAE10W 40 SAE5W 20 Capacity When the oil filter is not removed 1 5 L 1 6 US qt When the oil filter is removed 1 7 L 1 8 US qt e Check the O ring A on the oil filler cap for damage Re place the oil filler cap assembly if O ring is damaged When checking the oil level do not turn oil filler cap threads NOTE OSome increase in oil consumption may be expected when a multi grade engine oil 10W 30 10W 40 5W 20 is used Check the oil level more frequently than recom mended interval KF05004BS1 Oil Filter Replacement e Drain the engine oil see Engine Oil Change Using a suitable tool A remove the oil filter B OWhen unscrewing the oil filter place a suitable container beneath the oil drip tray to receive oil from the oil filter and oil passages in the engine e Replace the oil filter A with a new one e Apply light film of engine oil to the seal B e Install the oil filter Torque Oil Filter 11 8 1 2 kgf m 104 in Ib OTurn the filter until the seal contacts mounting surface C of the engine Then turn the filter BY HAND S 3 4 turn e Run the engine at slow idle speed 3 minutes OWhile running the engine check for oil leaks around it e Stop the engine and check the oil level see Engine Oil Level Inspection 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Spark Plug Cleaning and Inspecti
22. jet A main nozzle B and the main air passage C main air jet D The main system meters fuel to the engine dur Main System Fuel and Air Supply Air Cleaner ing moderate to heavy load conditions Fuel flows through Fuel Main PY the main jet and into the main nozzle where it is joined by Tank Jet air from the main air passage main air jet The resulting V mixture flows out the end of the main nozzle into the carbu Float Matna Niri ice Gto Chamber Passage Bore retor bore where it is atomized by the high speed air flow and carried into the engine 05205852 The pilot system includes the pilot jet E pilot screw F Pilot System Fuel and Air Supply idle mixture screw pilot air jet G pilot outlet H and the Fuel Float Main bypass holes I The pilot system meters the fuel air mixture Tank 22124 while the engine is idling and running under light load Under these conditions there is very little air flow through the carburetor bore so little that it is not enough to draw fuel through the main system of the carburetor and atomize it Instead the fuel is drawn through the pilot system since the nearly closed throttle valve J 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
23. 14 Engine Oll Level IrispectiOr ice tenete KEES EEN 2 14 Engine Oil GNange u 2 14 Oil Filter TE EE 2 15 Electrical SySteri u auld coe tos odd 2 16 Spark Plug Cleaning and 2 16 Spark Pl ug Gap INSpecti EE 2 16 2 2 PERIODIC MAINTENANCE Periodic Maintenance Chart To ensure satisfactory operation over an extended period of time any engine requires normal main tenance regular intervals The Periodic Maintenance Chart below shows periodic inspection and maintenance items and suitable intervals The bullet mark 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 First Daily 5 Check or clean air inlet screen 1 Check and add engine oil INTERVAL Every 100 hr Every 200 hr Every 300 hr Check for fuel and oil leakage Check for loose or lost nuts and screws Check battery electrolyte level Clean air cleaner foam element FS Models 1 Clean air cleaner paper element FS Models 1 Replace air cleaner paper element FS Models 1 Clean dust and dirt from cylinder and cylinder head fins 1 Tighten nuts and screws Change engine oil Clean and re gap spark plugs Change oil filter
24. 3 23 Inlet Manifold Installation urit poen rero Ee oa pe fe todo de Ree 3 23 Inlet Manifold 3 23 Fuel Pump Fuel Filter us a s sanan 3 24 F el Pup el Val EE 3 24 gr pm Ete EE 3 24 5 eet dedo a coa ira 3 24 Fuel Filter Removal Installation 3 25 F el Filter fo e ua I m oA 3 25 All ei e 3 26 Element 3 26 Element Installation 3 26 Element Cleaning and Inspection 3 27 3 2 FUEL SYSTEM Exploded View FS Models Exploded View FUEL SYSTEM 3 3 No Fastener Remarks kgf m ft Ib 1 Carburetor and Inlet Pipe Mounting Nut 5 9 0 60 52 ml 2 Control Panel and Inlet Pipe Mounting Nut 5 9 0 60 52 in lb 3 Float Chamber Mounting Screw Recoil 4 5 0 46 40 in lb Starter Model 4 Inlet Manifold Bolts S 5 Main Jet 6 Solenoid Valve Electric Starter Model 4 5 0 46 40 in lb 7 Throttle Valve Screws 0 68 0 069 6 0 in lb L 8 Recoil Starter Model L Apply a non permanent locking agent R Replacement Parts S Tighten the fasteners following the specified sequence 3 4 FUEL
25. B e Hold the reel A with spring side downward in a suitable container and tap reel to remove recoil spring B Recoil Starter Assembly A WARNING Wear gloves during the recoil spring installation to avoid injury The recoil spring must be assembled with great pressure e Lightly grease the recoil spring e Set the recoil spring into the reel e Wind the rope A clockwise B on the reel C e Lightly grease the shaft A e Install the reel B into the case C OHook the spring hook D to the case tab E e Turn the reel clockwise until you feel the spring hook catches the case tab KL03010BS1 STARTER SYSTEM 8 13 Electric Starter System e Install the pawls e Apply a non permanent locking agent to the recoil starter retainer screw A e Install the retainer assembly B e Tighten Torque Recoil Starter Retainer Screw 5 9 N m 0 60 kgf m 52 in Ib e Turn the reel two turns counterclockwise to preload the recoil spring e While holding the reel to keep it from unwinding feed the end of the rope through the hole in the case e Clip the rope as shown to hold it e Install the handle A and secure it with a knot B e Remove the clip C to release the rope ELECTRICAL SYSTEM 9 1 Electrical System Table of Contents Exp od ed eae cat ses eet eed Benue e e t adt PRU 9 2
26. Ground Resistance gt e Set the multimeter selector switch to the x 1 posi tion and measure the resistance between the negative brushes and starter motor yoke If the meter dose not read close 0 the yoke assembly is faulty Replace it Negative Brush to Ground Resistance Close 0 Q 090158 5 STARTER SYSTEM 8 11 Electric Starter System Recoil Starter Removal e Remove Recoil Starter Mounting Bolts A Recoil Starter B Recoil Starter Installation e Install the recoil starter A and tighten the mounting bolts B Torque Recoil Starter Mounting Bolts 5 9 0 60 kgf m 52 in Ib Recoil Starter Disassembly e Remove the recoil starter see Recoil Starter Removal e Pull the handle A out 30 cm 1 ft and clamp the rope B with the clip C so it can not wind back onto the reel D e Pry the knot E out of the handle and untie it e Remove the handle from the rope Wear gloves to avoid injury for the remaining steps e While carefully holding the reel A and case B remove the clip e Unwind the spring tension slowly NOTE ODo not wedge the rope between the reel and case HO Loosen the screw e Remove the retainer B with the snap ring C e Remove the pawls D KL03009BSi C 8 12 STARTER SYSTEM Electric Starter System e Slowly lift the reel A straight up out of the case
27. If the valve clearance is incorrect adjust it Valve Clearance when cold Inlet Exhaust 0 10 0 15 mm 0 0039 0 0059 in Valve Clearance Adjustment e Since valve repairs change the valve clearance adjust the valve clearance to the specified e Turn the crankshaft in proper direction until the piston is at the TDC of the compression stroke as described above e Loosen the locknut A and adjusting bolt B e Insert a 0 05 mm 0 0020 in thickness gauge C be tween the rocker arm and valve stem end and turn the adjusting bolt until the thickness gauge begins to bind be tween the rocker arm and valve stem end Sweep the thickness gauge during this adjustment Valve Clearance when cold Inlet Exhaust 0 10 0 15 mm 0 0039 0 0059 in PERIODIC MAINTENANCE 2 11 Periodic Maintenance Procedures e Holding the adjusting bolt with a spanner A tighten the adjusting locknut B to the specified torque Torque Valve Clearance Adjusting Locknuts 11 N m 1 1 kgf m 87 in Ib e Do not overtighten the valve clearance adjusting locknuts e After the valve clearance adjustment measure the valve clearance again Readjust the valve clearance if neces sary Valve Seat Inspection e Remove the valve see Valve Mechanism Removal Instal lation in the Engine Top End chapter e Inspect the valve seats for damage the seats are warped or distorted beyond recondition ing replace the
28. If the valve seating pattern is not correct repair the seat KM07018BS1 PERIODIC MAINTENANCE 2 13 Periodic Maintenance Procedures e Coat the seat with machinist s dye e Fit a 45 cutter A to the holder and slide it into the valve guide OResurface the valve seat with a 45 cutter removing only enough material to produce a smooth and concentric seat CAUTION Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced Do not turn the cutter counterclockwise or drop it against the seat or it will be dulled e Use a 32 seat cutter A to narrow the seat width to the standard width OTurn the seat cutter one turn at a time while pressing down very lightly Check the seat width after each turn CAUTION The 32 cutter removes material very quickly Check the seat width frequently to prevent over grinding NOTE OKeep the seat width as close as possible to the standard width e Make a light contact on the valve seat with the 45 cutter to remove any possible burrs at the edge of the seat e After resurfacing the seat inspect for even valve seating OApply a machinists dye to the valve face insert the valve and snap it closed against the seat several times The valve surface should show good
29. Install the choke valve and throttle valve on the shaft as the out side mark of them facing out side e Drive the float pin into the carburetor body e Assemble carburetor parts with recommended tightening torque see Exploded View Limiter Pilot Screw Spring Low Idle Speed Screw Spring Screws Throttle Valve Throttle Shaft Dust Seal 10 Choke Valve 11 Choke Shaft 12 Spring 13 Washer 14 Dust Seal E 15 Solenoid Valve Electric Starter Model 16 Gasket 17 Float Chamber 18 Gasket 05208883 19 Float Pin 20 Float 21 Main Jet 22 Main Nozzle 23 Float Valve 24 Screw Other than Solenoid Valve Type 5 0 3 20 FUEL SYSTEM Carburetor Carburetor Cleaning A WARNING Clean the carburetor in a well ventilated area and take care that there is no sparks or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean the carburetors CAUTION Do not use compressed air on an assembled carbu retor or the floats may be crushed by the pressure Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carbure tor with a cleaning solution This will prevent dam age to or deterioration of the parts The carburetor body has plastic parts that can not be removed Do
30. Loosen the cylinder head bolts 1 4 turn in the sequence as shown in the figure CAUTION If the above procedure is not followed the cylinder head may be warped during removal e Repeat the sequence until all bolts are removed and lift off the cylinder head assembly NOTE OMark the push rods and rocker arms so they can be installed in their original position during assembly ENGINE TOP END 5 9 Cylinder Head Cylinder Head Assembly Installation e Clean the mating surfaces of the cylinder heads and cylin ders e Replace the gaskets with new ones e Install the dowel pins A e Set each piston at the T D C A of the compression stroke e Put new gaskets and the cylinder head assemblies on each cylinder NOTE OAs the head gaskets are coated with sealing agents be careful not to damage the surfaces e Tighten the cylinder head bolts following the tightening sequence as shown in the figure Torque Cylinder Head Bolts 27 4 2 8 kgf m 20 ft Ib CAUTION A torque wrench must be used to assure proper torque Improper tightening of the head bolts may result in warping of the cylinder head 04048851 C e Install Rocker Arm Bracket see Valve Mechanism Removal In stallation Push Rod see Push Rod Installation Rocker Arm see Valve Mechanism Removal Installa tion e Install the new gaskets and rocker covers e Tighten the rocker cover bolts follo
31. SYSTEM Exploded View FUEL SYSTEM 3 5 Exploded View Torque No Fastener Nm ft Ib Remarks 1 Control Panel Mounting Bolt 5 9 0 60 52 inrlb 2 Governor Arm Clamp Nut 7 8 0 80 69 1 1 Governor Shaft Plate Screws 2 0 0 20 18 in lb EO Apply engine oil R Replacement Parts 3 6 FUEL SYSTEM Specifications Item Carburetor Specifications Make Type Electric Starter Model FS481V FS541V FS600V Recoil Starter Model FS481V FS541V FS600V Throttle Bore Diameter FS Models Venturi Diameter FS Models Main Jet MJ FS Models Pilot Jet PJ FS Models Pilot Air Screw Turns out PS Idle Mixture Screw Turns Out FS Models Float Level Standard LMF EX 1713 LMF EX 1712 LMF EX 1413E LMF EX 2036 LMF EX 2034 LMF EX 2032 24 mm 0 94 in 18 mm 0 71 in 102 50 1 5 8 1 2 Float parallel to carburetor body Idle Speed 1 Low Idle Speed Carburetor idle rpm Low Idle Speed Governor idle rpm High Idle Speed Air Cleaner Type Pre cleaner FS Models Second stage cleaner FS Models Fuel 2 Fuel Requirement US Canada Other Countries 1 450 r min rpm 1 550 r min rpm 3 600 r min rpm Dual stage filtration system Foam element Paper element Unleaded regular grade gasoline Using a minimum of 87 octane by antiknock index is recommended Antiknock Index RON MON 2 RON Research Octane Number MON Motor Oct
32. TOP END 5 7 Cylinder Head Compression Measurement e Before measuring compression do the following sure the battery is fully charged OThoroughly warm up the engine so that engine oil be tween the piston and cylinder wall will help sealing the compression as it does during normal running OStop the engine e Disconnect the spark plug caps of each cylinder and re move the spark plugs e Attach the compression gauge assembly firmly into one plug hole Special Tools Compression Gauge 20 kgf cm A 57001 221 Compression Gauge Adapter M14 x 1 25 B 57001 1159 e Ground the spark plugs to the engine WARNING To avoid fire do not ground the spark plugs in prox imity to the plug holes Keep the plugs as far away as possible from the plug holes Open the throttle fully Run the engine by turning the en gine switch key several times until the compression gauge stops rising Read the highest compression value Cylinder Compression MIN 448 kPa 64 psi O Engine Oil Temperature 50 60 122 140 F Cranking Speed 500 rpm 5 Seconds e Repeat the measurement on the other cylinder the compression is higher than the specified value the piston rings cylinder and valves are probably in good con dition the compression is too high check the following 1 Carbon build up on the piston crown and cylinder head clean off any carbon on the piston crown and cylinder head 2 Oylinder h
33. accumulated in the carburetor e Install the removed parts see appropriate chapters Recoil Starter Model e Place a suitable container under the carburetor e Remove Screw A Float Chamber B and gasket e Check if water or dirt has accumulated in the carburetor e Install the removed parts see appropriate chapters any water or dirt is found clean the carburetor see Carburetor Cleaning in the Fuel System chapter and fuel tank And check the fuel filter see Fuel Filter Inspection in the Fuel System chapter Periodic Maintenance Procedures Element Cleaning and Inspection Air cleaner elements are not recommended to be cleaned and each air cleaner element should be replaced with new ones at the maintenance time as shown in the maintenance chart NOTE OOperating in dusty condition may require more frequent maintenance than above FS Models e Remove the foam and paper elements see Air Cleaner Element Removal e Clean the foam element A in a bath of detergent and water and let the element air dry thoroughly e Clean the paper element B by tapping it gently on a flat surface to remove dust If the element is very dirty re place it with a new one Engine Top End Cylinder Head Cleaning e Scrape the carbon deposits from the cylinder head and the exhaust port with a suitable tool A OTo avoid gouging use scrapers that are made of a mate rial that will not cause damage e Clean the head in a bath
34. and tighten the mounting bolts Olnstall the hook A so that the stopper B of the hook contacts the crankcase Torque Starter Motor Mounting Bolts 19 6 2 00 kgf m 14 4 ft Ib Starter Motor Disassembly FS Models e Remove Through Bolts A Brush Plate Assembly B e Remove York A Nut B Washer C Spring D Pinion Gear E Rubber Damper F Collar G End Cover H Starter Motor Assembly FS Models e Using the suitable tool hold the brushes e Install the armature assembly to the brush plate assem bly 8 8 STARTER SYSTEM Electric Starter System e Install the yoke so that the slit A fit the groove B of the brush plate assembly Apply grease to the armature shaft e Install the end cover so that the slit A fit the projection B of the yoke e Tighten Torque Starter Motor Through Bolts 3 95 0 40 kgf m 35 in lb e Install Collar A Rubber Damper B Pinion Gear C Spring D Washer E e Make sure that grease does not attach to the contact por tion between the collar and the rubber damper e Tighten the nut F Starter Motor Brush Inspection e Measure the overall length A of each brush the brushes are shorter than the service limit replace them Brush Length Standard FS Models Service Limit FS Models 10 16 mm 0 4 in Brush Spring Inspection e Inspection the brush springs for pitting cracks rusting and burrs
35. avoid distortion of the part and or causing gas or oil leakage Conversely when loosening the bolts nuts or screws first loosen all of them by about a quarter of a turn and then remove them Where there is a tightening sequence indication in this Service Manual the bolts nuts or screws must be tightened in the order and method indicated 4 Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench 5 Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removal of screws held by a locking agent in order to avoid damaging the heads 6 Edges Watch for sharp edges especially during major engine disassembly and assembly Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over 7 High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent com monly available in North America is Standard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent 8 Gasket O ring Do not reuse a gasket or O ring once it ha
36. 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 Rocker Arm Inspection e Measure the diameter A of the rocker shafts with a mi crometer at several points of bearing the rocker arm the outside diameter is less than the service limit re place the rocker shaft Rocker Shafts Outside Diameter Service Limit Inlet Exhaust 10 91 mm 0 430 in e Clean and inspect the rocker arm where it touches the push rod and valve stem the contact points A are worn or damaged replace the rocker arm e Measure the inside diameter B of the rocker arm at sev eral points using a dial bore gauge or inside micrometer the inside diameter is more than the service limit re place the rocker arm Rocker Arm Inside Diameter Service Limit Inlet Exhaust 11 13 mm 0 438 in ENGINE TOP END 5 13 4042851 C KE048148 P 5 14 ENGINE TOP END Valves Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Clearance Adjustment e Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Seat Inspection e Refer to the Valve Seat Inspection in the Periodic Mainte nance chapter Valve Seat Repair e Refer to the Valve Seat Repair in the Periodic Mainte nance chapter Valve Head Thickness
37. cover gasket with a new one e Install Breather Pipe see Breather Pipe Installation Gasket Breather Chamber Cover A e Tighten Torque Breather Chamber Cover Bolts B 5 9 N m 0 60 kgf m 52 in Ib e Attach the stop switch lead C to the breather chamber cover with the band D e Install the removed parts see appropriate chapters Breather Valve Inspection e Inspect the reed valve A for breakage crack or distor tion replace it with a new one if necessary e Inspect the plate B for damage or rough contact surface replace it with a new one if necessary e Inspect the valve seating surface The surface should be no nicks or burrs Breather Pipe Removal e Remove Breather Chamber Cover see Breather Valve Removal Breather Pipe A Breather Pipe Installation e Install the breather pipe A e Install the removed parts see appropriate chapters 7 14 CAMSHAFT CRANKSHAFT Camshaft Tappet Camshaft Tappet Removal e Set the engine on a clean surface while parts are re moved e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Crankcase Cover see Crankcase Cover Removal Cylinder Head Assembly see Cylinder Head Assembly Removal in the Engine Top End chapter e Turn the crankcase upside 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 th
38. necessary Fuel Shut Off Solenoid Valve Test Electric Starter Model e Unscrew the fuel shut off valve A and remove it e Connect a 12 VDC source to the solenoid as shown in the figure If the actuated solenoid plunger Needle Valve does pop out when the Test Voltage is applied replace it with a new one NOTE Olf necessary push the plunger slightly for the plunger to withdraw KCO5011BS1 KC05199BS1 KC05178BS1 FUEL SYSTEM 3 23 Inlet Manifold Inlet Manifold Removal e Remove the carbretor see Carbretor Removal e Unscrew the inlet manifold mounting bolts A e Remove the inlet manifold B and gaskets Inlet Manifold Installation e Replace the inlet manifold gaskets A with new ones e Clean the mating surfaces of the cylinders and Inlet man ifolds e Install the inlet manifold gaskets e Install the inlet manifold e Tighten the inlet manifold mounting bolts following the tightening sequence Torque Inlet Manifold Mounting Bolts 5 9 0 60 kgf m 52 in Ib e Install the removed parts see appropriate chapters Inlet Manifold Inspection e Inspect the intake manifold for cracks or porous casting e Cracks not visible to the eye may be detected by using a metal crack detection system Visual color check com monly found at automotive parts store crack is present in the inlet manifold replace it e Inspect the gasket surfa
39. not use a strong carburetor cleaning solution which could attack these parts instead use a mild high flash point cleaning solu tion safe for plastic parts Do not use wire or any other hard instrument to clean carburetor parts especially jets as they may be damaged e Disassemble the carburetor see Carburetor Disassem bly Assembly e Immerse all the carburetor metal parts in a carburetor cleaning solution and clean them e Rinse the parts in water and dry them with compressed air e Do not use rags or paper to dry parts Lint may plug the holes or passages e Blow air through the holes and fuel passages with the compressed air All holes must be open e Assemble the carburetor see Carburetor Disassem bly Assembly FUEL SYSTEM 3 21 Carburetor Carburetor Inspection A WARNING Gasoline is extremely flammable and can be explo sive under certain Turn the engine switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Inspect the carburetor body for damage Flange sealing surfaces should be smooth and free of burns and nicks e Turn the throttle and choke shafts to check that the throttle and choke butterfly valves move smoothly lf the valves do not move smoothly replace the carburetor body and or throttle shaft and choke shaft assembly with new ones e Check the gasket on the carburetor body
40. of the throttle valve through the bypass holes and pilot outlet While the throt tle valve is almost closed it covers the small bypass holes opening into the bore from the pilot system As the throttle valve begins to open it uncovers the bypass holes allow ing more fuel air mixture to flow The extra flow is needed because the engine starts to run faster as the throttle is opened The pilot screw controls the amount of fuel air mixture allowed through the pilot outlet but does not me ter the bypass holes A moderate amount of air comes in around the throttle valve at idle so adjusting the pilot screw changes the fuel air ratio Turning the pilot screw idle mix ture screw out counterclockwise enriches the mixture turning it in clockwise leans the mixture Main Fuel Flow gt Pilot Fuel Flow Main System Fuel and Air Supply Fuel Main Engin Tank Jet ibis Float Main Air Chamber Passage Main Jet SSA SCH E lt 05203852 Pilot System Fuel and Air Supply Fuel Float Main Tank Chamber Jet Pilot Pilot Air Air Jet Passage Pilot lt Outlet ws 93 SN 05204852 FUEL SYSTEM 3 13 Carburetor Recoil Starter Model The main system of the carburetor consists of the main
41. oil pump cover plate see Oil Pump Relief Valve Removal e Remove the oil screen A Oil Screen Installation Clean the oil screen thoroughly whenever it is removed for any reason see Cleaning and Inspection e Insert the oil screen A in position e Install the oil pump cover plate see Oil Pump Relief Valve Installation Cleaning and Inspection Clean the oil screen A with high flash point solvent and A remove any particles stuck to it WARNING Clean 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 00919 P NOTE OWhile cleaning the screen check for any metal particles that might indicate internal engine damage e Check the screen carefully for any damage holes and broken wire If the screen is damaged replace it with a new CAMSHAFT CRANKSHAFT 7 1 Camshaft Crankshaft Table of Contents PDT EE RES 7 2 Specification Sisa ese edet bas o diese es 7 4 EEE ML Duft d M LM 7 5 GrarikedSe eeh eg 7 6 Crankcase Cover Remosval ege M au Evo rds due enn 7 6 Crankcase Cover Disassembly e 7 6 Grankcase Cover Assembly uie ed ee ap
42. or dirt on the fol lowing portions and dry them with a clean cloth Crankshaft Tapered Portion A Flywheel Tapered Portion B e Fit the woodruff key C securely in the slot in the crank shaft before installing the flywheel 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 Putthe washer A as shown so that the 0 mark B faces up e Tighten Torque Flywheel Bolt C 56 5 7 kgf m 41 ft Ib e Install the ignition coils see Ignition Coil Installation e Install the cooling fan A e Tighten Torque Cooling Fan Mounting Bolts B 8 8 N m 0 90 kgf m 78 in lb KH07043BS1 ELECTRICAL SYSTEM 9 15 Charging System e Attach the stator coil lead A ignition coil lead and sole noid valve connector lead to the engine shroud with the band B e Install the fan housing e Tighten Torque Fan Housing Bolts 8 8 N m 0 90 kgf m 78 in Ib e Install the cooling fan screen e Tighten Torque Cooling Fan Screen Screws 3 0 N m 0 31 kgf m 27 in Ib e Install the guard A so that the projection B insert into the slot C in the fan housing e Screw the screw rivets e Install the removed parts see appropriate chapters Recoil Starter Model e Install the stator coil and tighten the screws Torque Stator Coil Screws 3 4 0 35 kgf m 30 in Ib e Using a cleaning fluid
43. so that the flatten side faces flywheel side e Insert the washers onto the valve clearance adjusting bolts and install them from the PTO side hole of the rocker arms OAlign the flatten surface of the collars with the flatten sur face of the valve clearance adjusting bolts e Tighten the valve clearance adjusting locknuts temporar ily Position the push rod end on to the rocker arm hollow e Adjust the valve clearance see Valve Clearance Adjust ment in the Periodic Maintenance chapter Cylinder Head Cleaning e Refer to the Cylinder Head Cleaning in the Periodic Main tenance chapter KE04044BS1 Cylinder Head Cylinder Head Inspection 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 If warp exceeds the service limit repair the head by lap ping the mating surface with emery paper secured to a surface plate first No 200 than No 400 If the mating surface is badly damaged replace the cylinder head 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 2596 kerosene and 7596 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
44. via the pilot air jet in the mouth of the carburetor The fuel air mixture passes into the bore of the carburetor side stream of the throttle valve through the bypass holes and pilot outlet While the throt tle valve is almost closed it covers the small bypass holes opening into the bore from the pilot system As the throttle valve begins to open it uncovers the bypass holes allow ing more fuel air mixture to flow The extra flow is needed E 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 me ter the bypass holes A moderate amount of air comes in around the throttle valve at idle so adjusting the pilot screw changes the fuel air ratio Turning the pilot screw idle mix ture screw out counterclockwise enriches the mixture turning it in clockwise leans the mixture Main Fuel Flow Pilot Fuel Flow 3 14 FUEL SYSTEM Carburetor Fuel Shut Off Solenoid Valve Electric Starter Model To avoid after firing when stopping the engine a solenoid actuated fuel shut off solenoid valve A is installed in the carburetor bowl The valve shuts off the fuel supply to the q H main jet B simultaneously when the switch key turned to eer the OFF position DSSS Si E La sss I N II ESS ES The valve opens automatically when the swi
45. 5 96 mm 0 628 in KE06012BS1 e Measure the inside diameter A of the piston pin hole at several points on both side Use a dial bore gauge the inside diameter is greater than the service limit re place the piston with a new one mon Piston Pin Hole Inside Diameter Service Limit 16 08 mm 0 633 in 6117851 C e Measure the inside diameter A of the connecting rod small end at several points Use a dial bore gauge lf the inside diameter is more than the service limit re place the connecting rod with a new one Connecting Rod Small End Inside Diameter Service Limit 16 05 mm 0 632 in 06126851 C 5 22 ENGINE TOP END Cylinder Piston Piston Diameter e Measure the outside diameter A of the piston 11 mm 0 43 in B up from the bottom of the piston at a right angle to the direction of the piston pin hole the measurement is less than the service limit replace the piston with a new one Piston Diameter Service Limit 72 79 mm 2 866 in Cylinder Inside Diameter e Clean and measure the cylinder inside diameter OUse a cylinder gauge to measure front to back and side to side at the points as shown in the figure any of the cylinder inside diameter measured value is greater than the service limit replace the crankcase with a new one 10 mm 0 39 in A 40 mm 1 6 in B 25 mm 0 98 in C Cylinder Inside Diamet
46. 924 2094 01 Printed in Japan
47. B 8 8 N m 0 90 kgf m 78 in Ib e Install the spark plug caps C e Attach the stator coil lead A stop switch lead and sole noid valve connector lead to the engine shroud with the band B e Install the removed parts see appropriate chapters COOLING SYSTEM 4 9 Engine Shroud Recoil Starter Model e Install the engine shrouds A e Tighten Torque Engine Shroud Bolts B 8 8 0 90 kgf m 78 in Ib e Install the spark plug caps C e Attach the stator coil lead A and stop switch lead B to the engine shroud with the band C e Install the removed parts see appropriate chapters ENGINE TOP END 5 1 Engine Top End Table of Contents Exploded NIEWEN IMS 5 2 ee decia tae abre eae Uc LL S 5 4 See Cr 5 6 Gylinder F leadu uu iet bes EE DU eL 5 7 Compression Measurement 5 7 Cylinder Head Assembly Removal pp 5 8 Cylinder Head Assembly Installation pp 5 9 P sh Rod Removal p 5 10 P sh Rod Installation aun cba se tetra 5 10 Push Rod Inspection eerte Dd ee stipe rodent Main eer debe deben ense 5 10 Valve Mechanism Removal Installation pp 5 10 Cylinder Head Cleaning nike teret ood 5 12 Cylinder Head Inspector teet tario d usines 5 13 Rocker Arm Inspegtlori euo oe i tese oce table 5 13
48. ECTRICAL SYSTEM Charging System e Using a suitable flywheel puller A remove the flywheel B CAUTION Always use flywheel puller e Cut off the band A Free the stator coil lead from the clamp e Remove Woodruff Key A Stator Coil Screws B Stator Coil C Recoil Starter Model e Remove Recoil Starter see Recoil Starter Removal in the Starter System chapter Element Assembly see Element Removal in the Fuel System chapter Fuel Pump see Fuel Pump Removal in the Fuel System chapter Nuts A Recoil Starter Plate B e Remove Bolts A Fan Housing B ELECTRICAL SYSTEM 9 13 Charging System e Remove the fan housing stud bolts A e Remove the ignition coils see Ignition Coil Removal e Hold the flywheel with a suitable tool A remove the fly wheel bolt and washer e Remove the pulley B with the screen C e Remove Pulley Plate A Bolts B Cooling Fan Plate C Cooling Fan D e Using a suitable flywheel puller A remove the flywheel B CAUTION Cut off the band A 9 14 ELECTRICAL SYSTEM Charging System e Remove Woodruff Key A Stator Coil Screws B Stator Coil C Flywheel and Stator Coil Installation Electric Starter Model e Install the stator coil and hold the stator coil lead to the clamp e Tighten Torque Stator Coil Screws 3 4 N m 0 35 kgf m 30 in Ib e Using a cleaning fluid clean off any oil
49. Exhaust 29 62 mm 1 166 in 6 11012251 e Measure both camshaft journal diameter A at several points around the journal circumference the journal diameter is less than the service limit re place the camshaft with a new one Camshaft Journal Diameter Service Limit PTO Side 15 99 mm 0 630 in Flywheel Side 15 99 mm 0 630 in e Measure the inside diameter A of the camshaft insert on the crankcase at several points the inside diameter is more than the service limit re place the crankcase with a new one Camshaft Bearing Inside Diameter Crankcase Service Limit 16 14 mm 0 635 in 7 16 CAMSHAFT CRANKSHAFT Camshaft Tappet e Measure the inside diameter A of the camshaft insert on the crankcase cover at several points If the inside diameter is more than the service limit re place the crankcase cover with a new one Camshaft Bearing Inside Diameter Crankcase Cover Service Limit 16 14 mm 0 635 in CAMSHAFT CRANKSHAFT 7 17 Crankshaft Connecting Rod Connecting Rod Removal e Remove the piston see Piston Removal in the Engine Top End chapter Connecting Rod Installation e Install the piston see Piston Installation in the Engine Top End chapter Crankshaft Removal e Remove Camshaft see Camshaft Tappet Removal Connecting Rod and Pistons see Piston Removal in the Engine Top End chapter e Pull the crankshaft A out of the crankcase Tap gently with a woode
50. OP END 5 17 6 16060651 06045 51 06128851 6105851 5 18 ENGINE TOP END Cylinder Piston e Apply engine oil to the piston pins e Assemble the pistons onto the connecting rods as follow ONo 1 Cylinder Piston align the arrow mark on the piston head with opposite Mark on the connecting rod to face the flywheel side ONo 2 Cylinder Piston align the arrow mark on the piston crown with the mark on the connecting rod OBoth marks must face the flywheel side No 1 cylinder Piston A No 2 cylinder Piston B Arrow Marks C K Mark D Opposite Mark E e Fitanew piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the notch B in the edge of the piston pin hole OWhen installing a piston pin snap ring compress it only enough to install it and no more CAUTION Do not reuse the snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Apply engine oil to the piston skirt and the cylinder bore e Using the piston ring compressor grip A and the belt B lightly tap the top of the piston with a plastic mallet C to insert the piston and connecting rod into the cylinder Special Tools Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 67 79 57001 1097 e Insert the piston and connecting rod so that the
51. Refer to the equipment specification 2 6 PERIODIC MAINTENANCE Special Tools Valve Seat Cutter 45 627 5 57001 1114 5157111451 Valve Seat Cutter 45 532 57001 1115 Valve Seat Cutter 32 28 57001 1119 ST571115ST ST571119ST Valve Seat Cutter Holder Bar 57001 1128 875711285 Valve Seat Cutter 32 533 57001 1199 Valve Seat Cutter Holder 6 57001 1360 7571199ST ST571360ST Periodic Maintenance Procedures Fuel System NOTE OHigh and low idle speeds may vary depending on the equipment on which the engine is used Refer to the equipment specification Low Idle Speed Adjustment e Disconnect all possible external loads from the engine e Start the engine and warm it up thoroughly WARNING Always keep your hands clear of the moving parts e Move the throttle lever at a dash to the idle position e Hold the throttle lever on the carburetor in closed position turn the governor arm clockwise all the way and adjust the low idle speed screw A until the engine idles at spec ified speed Low Idle Speed Carburetor idle rpm 1 450 r min rpm e Release the throttle lever e Loosen the locknut A e Adjust the low idle speed set screw B on the control plate to obtain the specified governor low idle speed Low Idle Speed Governor idle rpm 1 550 r min rpm e Tighten the locknut
52. Remarks N m kgf m ft Ib 1 Engine Oil Drain Plug 6 9 0 70 61 mb 2 Oil Filler Mounting Bolt 8 8 0 90 78 mb 3 Oil Filter 11 8 1 2 104 in lb R 4 Oil Pump Cover Plate Bolts 5 9 0 60 52 mb EO Apply engine oil G Apply grease R Replacement Parts 6 4 LUBRICATION SYSTEM Engine Oil Flow Chart d d d amp 0 AA z Y ZW NN p E GC 555 KF04014BW5 C Specifications LUBRICATION SYSTEM 6 5 Item Standard Engine Oil Grade SJ or higher class Viscosity SAE40 SAE30 SAE10W 30 SAE10W 40 or SAE5W 20 Capacity When the oil filter is not 1 5 L 1 6 US qt removed When the oil filter is removed Level 1 7 L 1 8 US qt Operating range grid area ADD and FULL on dipstick Cil Pressure 294 to 686 kPa 43 to 99 psi Engine oil temperature 50 C to 60 122 144 F 93 200 r min rpm Item Service Limit Pump Inner and Outer Rotor Clearance Outer Rotor Outside Diameter Outer Rotor Thickness Pump Housing Inside Diameter Pump Housing Depth Relief Valve Spring Free Length 0 2 mm 0 008 in 52 31 mm 2 059 in 14 91 mm 0 5870 in 52 72 mm 2 076 in 15 16 mm 0 5968 in 20 4 mm 0 803 in 6 6 LUBRICATION SYSTEM Special Tools Oil Pressure Gauge 10 kgf cm 57001 164 7570164ST C Oil Pressure Gauge Adapter PT 1 8 57001 1033
53. Replace the spring if necessary e Inspect the springs for weakened conditions and distor tion Replace the spring if necessary the brush springs are able to press the brushes firmly into place they may be considered serviceable If they cannot replace them Electric Starter System Armature Inspection e Inspect the surface of the commutator x lf it is scratched or dirty polish it with a piece of very fine emery cloth B and clean out the grooves e Measure the depth of the grooves between the commu tator segments the grooves are shallower than the specified limit re place the armature with a new one xIf the grooves are only dirty clean them carefully Commutator Groove Depth Standard FS Models Service Limit FS Models 1 27 mm 0 05 in Bad A Segment B Good C 1 27 mm 0 05 in limit D Mica E e Measure the outside diameter A of the commutator B at several points the diameter is less than the service limit replace the armature with a new one Commutator Outside Diameter Standard FS Models Service Limit FS Models 31 369 mm 1 235 in e Support the armature in an alignment jig at each end of the shaft as shown Position a dial indicator perpendicular to the commutator e Rotate the armature slowly and read the commutator runout runout is more than the service limit replace the arma ture with a new one Commutator Runo
54. ane Number Using a minimum of 91 octane by RON is recommended Fuel Pump Type Pulse diaphragm pump Governor Type Flyweight all speed governor FUEL SYSTEM 3 7 Specifications 1 Idle speeds may vary depending on each equipment Refer to the equipment specification 2 Other fuel requirements See Fuel and oil recommendations in Owner s Manual 3 8 FUEL SYSTEM Governor Link Mechanism Control Panel Assembly Removal e Remove Control Panel and Inlet Pipe Mounting Nut A Control Panel Mounting Bolt B Electric Starter Model C Recoil Starter Model D e Remove the control panel assembly A while unhooking the governor spring B end loop at the panel bracket 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 If any part is worn or damaged replace the control panel assembly with a new one e Hookthe governor spring A end loop to the control panel bracket B FUEL SYSTEM 3 9 Governor Link Mechanism e Install the control panel assembly A e Tighten kgf m 52 in Ib Control Panel and Inlet Pipe Mounting Nut C 5 9 N m 0 60 kgf m 52 in Ib e After installation adjust the low idle speed and high idle speed to the specifications see Low High Idle Speed Ad justment in the Periodic Maintenance chapter Electric Starter M
55. arance see Valve Clear ance Inspection in the Periodic Maintenance chapter Push Rod Inspection e Place the push rod on V blocks as far apart as possible and set a dial gauge A on the rod at a halfway point between the blocks Turn the rod to measure the runout The difference between the highest and the lowest dial readings is the amount of runout If the runout exceeds the service limit replace the rod with a new one Rocker Arm Push Rod Runout Service Limit TIR 0 5 mm 0 02 in Valve Mechanism Removal Installation NOTE OWhen removing the valve mechanism parts note their position so that they may be reinstalled in their original position during assembly KE04007BS1 C Cylinder Head e Remove Valve Clearance Adjusting Locknuts A Valve Clearance Adjusting Bolts B and Washer Collar Rocker Arm C e Remove Push Rod see Push Rod Removal Rocker Arm Bracket Bolts A Rocker Arm Brackets B e Remove the cylinder head assembly see Cylinder Head Assembly Removal e Support the valve head in the combustion chamber with a suitable block e To remove the collets A push down the valve retainer B with suitable tool and remove the collets e Remove the valve retainer spring C and valve D e Remove the stem seals A NOTE Olt is not necessary to remove the stem seal unless it is being replaced O Valve guide B is not replaceable do no remove it e Apply engine oil to t
56. arrow mark A on the top of the piston is facing the flywheel side KE06127BS1 Cylinder Piston CAUTION The connecting rod and the connecting rod big end cap are machined at the factory in the assembled state so they must be replaced together as a set e Apply molybdenum disulfide oil solution oil to the inner surface A of the connecting rod big end B and caps C OThe molybdenum disulfide oil solution is a mixture of en gine oil and molybdenum disulfide grease with a weight ratio 10 1 e Install the connecting rod big end caps on their original position on each connecting rod big ends e Apply a thin layer of engine oil to the thread D and seat ing surface E of the cap bolts e Tighten Torque Connecting Rod Big End Cap Bolts 9 8 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters Piston Cylinder Seizure e n case of seizure remove the pistons see Piston Re moval e Visually inspect the cylinder and pistons for damage there is only light damage repair the damaged piston surface with 400 emery cloth Remove the small alu minum deposits from the cylinder with 400 emery cloth or light honing the damage is severe replace the crankcase and pis tons Piston Cleaning e Remove the piston and piston rings see Piston Re moval CAUTION Never clean the piston head with the engine assem bled Carbon particles will fa
57. between the highest and lowest dial gauge read ings TIR is the amount of runout the measurement exceeds the service limit replace the crankshaft with a new one KG06043BSi Crankshaft Runout Service Limit TIR 0 05 mm 0 002 in 7 20 CAMSHAFT CRANKSHAFT Crankshaft Connecting Rod 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 re place the crankshaft with a new one Crankshaft Journal Diameter Service Limit PTO Side A 37 90 mm 1 492 in Flywheel Side B 34 90 mm 1 374 in STARTER SYSTEM 8 1 Starter System Table of Contents Exploded VIEW cud adeo oit e bo C def code e 8 2 erzielen 8 6 Electric Starter 8 7 Starter Motor Removal ueteri Ren tende mace eee 8 7 Starter Motor Installation pp 8 7 Starter Motor Disassembly tne tret tH er 8 7 Starter Motor Assembly pp 8 7 Starter Motor Brush Inspection pp 8 8 Br sh Spring Inspesllon ss acoso ds eoe D NV entem mto aot 8 8 Armature Inspection NS duda qus 8 9 tel ale Uer EE 8 10 Recoil Starter Removal tee 8 11 Recoil Starter nstallatig 8 11 Recoil Starter Disassembly
58. ces for burrs and nicks 3 24 FUEL SYSTEM Fuel Pump Fuel Filter The diaphragm in the fuel pump operates by the pulse generated in the crankcase and the fuel pump supplies fuel to the carburetor The fuel pump disassembly is not recommended if any damage for the pump is noticed replace it with a new one Fuel Pump Removal e Remove Fuel Tubes A Pulse Tube B Screws C Fuel Pump D Fuel Pump Installation e Connect the fuel tubes A and pulse tube B fully e Tighten the fuel pump mounting screws C Fuel Pump Inspection e Check the vent holes A and filter B for plugging or clog ging If vent hole and filter are plugged or clogged remove the foreign material from them FUEL SYSTEM 3 25 Fuel Pump Fuel Filter Fuel Flow Test WARNING Gasoline is extremely flammable and can plosive under certain conditions Turn the engine switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Disconnect the 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 xIf fuel flow is none or little replace the fuel pump with a new one Check for clogged or damaged tubes and fuel filter Re place the faulty parts Fuel Filter Remo
59. clean off any oil or dirt on the fol lowing portions and dry them with a clean cloth Crankshaft Tapered Portion A Flywheel Tapered Portion B e Fit the woodruff key C securely in the slot in the crank shaft before installing the flywheel 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 cooling fan A e Install the plate B so that the slits C fit to the bosses D on the fan e Tighten Torque Cooling Fan Plate Mounting Bolts 8 8 0 90 kgf m 78 in Ib 9 16 ELECTRICAL SYSTEM Charging System e Install the pulley plate A so that the notch B inserts into the slot C in the flywheel e Install the pulley A with the screen B so that the tabs C of the plate D fit into the holes E e Putthe washer A as shown so that the 0 mark B faces up e Tighten Torque Flywheel Bolt C 56 N m 5 7 kgf m 41 in Ib e Install the ignition coils see Ignition Coil Installation KH07043BS1 e Attach the stator coil lead A and stop switch lead B to the engine shroud with the band C e Install the crankcase stud bolts and tighten them Torque Fan Housing Stud Bolts 5 9 N m 0 60 kgf m 52 in Ib e Install the fan housing and tighten the bolts Torque Fan Housing Bolts 5 9 N m 0 60 kgf m 52 in Ib e Install the recoil starter plate and tighten the nut
60. 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 xlf the seat does not make proper contact lap the valve into seat with a lapper e Coat the face of valve sparingly with a fine lapping com pound Use the lapping 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 5006 51 C 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures e When lapping is completed wash all parts in solvent to remove lapping compound Dry the parts thoroughly Note the position of the lapping mark on the valve face The lapping mark should appear on or near the center of the valve face e When the engine is assembled be sure to adjust the valve clearances see Valve Clearance Adjustment Lubrication System Engine Oil Level Inspection e Place the engine on a level surface e Remove the oil filler cap A and wipe its dipstick B with a clean cloth e Insert the dipstick into tube C without screwing it in then check the oil level e The oil level should be the operating range grid area D on the dipstick the oil level is ADD range E add enough engine oil to bring oil level to t
61. crometer to measure at several points around the rings lf any of the measurement are less than the service limit replace the entire set of rings with new ones Piston Ring Thickness Service Limit Top 1 1 mm 0 043 in Second 1 1 mm 0 043 in NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston with a new one KE06038BS1 C KE06038BS1 C 06010851 ENGINE TOP END 5 21 Cylinder Piston Piston Ring End Gap e Remove the piston rings see Piston Removal e Push each ring one at a time in the cylinder bore to a point close to the bottom of the cylinder bore OUse the piston to push it in to be sure it is square e Measure the gap A between the ends of the ring B with a thickness gauge If the end gap of any ring is greater than the service limit replace the entire set of rings with new ones 6124851 C Piston Ring End Gap Service Limit Top 0 7 mm 0 028 in Second 0 9 mm 0 035 in Cil 1 05 mm 0 041 in Piston Pin Piston Pin Hole and Connecting Rod Wear e Remove the piston pin see Piston Removal e Measure the outside diameter of the piston pin with a mi crometer at several points the outside diameter is less than service limit replace the piston pin with a new one Piston Pin Outside Diameter Service Limit 1
62. cylinder head with a new one e Pitted or worn valve seats can be refaced Lap the valves to the seats after refacing e Coat the valve seat with machinist s dye e Push the valve into the guide e Rotate the valve against the seat with a lapping tool e Pull the valve out and check the seating pattern on the valve head It must be the correct width A and even all the way around KE05004BSi NOTE OThe valve stem and guide must be in good condition or this check will not be valid Good A Too Wide B Too Narrow C Uneven D xIf the valve seating pattern is not correct repair the seat Valve Seating Surface Width STD Exhaust 0 8 1 4 mm 0 031 0 055 in Inlet 0 8 1 4 mm 0 031 0 055 in 05003851 Valve Seat Repair e Follow the manufacture s instructions for use of valve seat cutters Special Tools Valve Seat Cutter Holder Bar 57001 1128 Valve Seat Cutter Holder 57001 1360 Exhaust Valve Valve Seat Cutter 45 627 5 57001 1114 Valve Seat Cutter 32 528 57001 1119 Inlet Valve Valve Seat Cutter 45 532 57001 1115 Valve Seat Cutter 32 033 57001 1199 x f the manufacture s instructions are not available use the following procedure 2 12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Seat Cutter Operating Cares 1 This valve seat cutter is designed only for valve seat repair Therefore the cutter
63. d at the primary winding L1 allowing a small bias current to flow from the control resister R1 to the transistor Q1 base and thereby exciting the transistor base Thus the transistor forms turns ON the primary circuit This circuit current flows from the plus side of the primary winding to ground through the transistor Collector C to Emitter E When the base current is flowing the trigger sensor TS1 detects optimum time peak current to shut off the transistor base current With the transistor rapidly shutting off the current at the primary coil counter electromotive force is generated and voltage in hundreds volts is induced through the primary winding L1 thereby producing extremely high voltage at the secondary winding L2 When this secondary voltage steps up to k volts ionization meaning ignition occurs across the electrodes at the spark plug SP The trigger sensor located internally in the ignition system is set to give constant ignition timing according to engine speed and temperature The diode D1 located at the ignition shut off circuit prevents misconnection of battery voltage protecting the internal components of the ignition system When the stop switch SW is set at the closed position primary voltage is routed to ground not allowing igniting operation Ignition System Ignition Coil Removal e Remove the fan housing see Flywheel and Stator Coil Removal e Cut off the band A e Remove Spark P
64. d Twist Connecting Rod Big End Width Crankpin Width Connecting Rod Big End Inside Diameter Crankpin Outside Diameter Crankshaft Runout Crankshaft Journal Diameter PTO Side Flywheel Side Crankcase Crankshaft Bearing Inside Diameter Crankcase Crankshaft Journal Bearing Inside Diameter Crankcase Cover TIR 0 15 100 mm 0 006 3 94 in TIR 0 15 100 mm 0 006 3 94 in 19 00 mm 0 748 in 40 0 mm 1 57 in 38 04 mm 1 50 in 37 94 mm 1 49 in TIR 0 05 mm 0 002 in 37 90 mm 1 492 in 34 90 mm 1 374 in 35 10 mm 1 382 in 38 10 mm 1 500 in CAMSHAFT CRANKSHAFT 7 5 Special Tool Bearing Driver Set Gasket Liquid TB1217H 57001 1129 92104 7001 7571129ST 879270015 7 6 CAMSHAFT CRANKSHAFT Crankcase Crankcase Cover Removal e Set the engine on a clean surface while parts are being removed e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Oil Filter see Oil Filter Replacement in the Periodic Maintenance chapter Inlet Manifold see Inlet Manifold Removal in the Fuel System chapter Engine Shrouds see Engine Shroud Removal in the Cooling System chapter Ignition Coils see Ignition Coil Removal in the Electrical System chapter Flywheel and Stator Coil see Flywheel and Stator Coil Removal in the Electrical System chapter Starter Motor see Starter Motor Removal in the Starter System chapter Elect
65. d 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 CAMSHAFT CRANKSHAFT 7 9 Crankcase e Be sure to replace any oil seal with a new one if removed OApply mineral oil to the crankshaft oil seal outside Olnstall the oil seal so that the marks A face out OThoroughly pack high temperature grease to 6096 volume into the space B between the dust lip C and seal lip D Press in the new oil seal using a press or suitable tools until it is flush with flange surface E or maximum 1 mm 0 04 in F lower than the flange surface Do not damage the seal lip Flywheel Side G e Install the removed parts see appropriate chapters Crankcase Inspection e Measure the inside diameter A of the crankshaft in sert on the crankcase at several points Replace the crankcase if the inside diameter is more than the service limit Crankshaft Bearing Inside Diameter Service Limit 35 10 mm 1 382 in Crankcase and Crankcase Cover Cleaning e Remove Oil Pump and Relief Valve see Pump Relief Valve Removal in the Lubrication System chapter Camshaft and Tappets see Camshaft Tappet Removal Crankshaft see Crankshaft Removal Breather Valve and Cover see Breather Valve Removal e Clean up the crankcase and cover
66. d tester to the R x 1 kO range Special Tool Hand Tester 57001 1394 OMeasure the ignition coil winding resistance as shown in the table Ignition Coil Winding Resistance ELECTRICAL SYSTEM 9 23 P CAUTION room temperature for this test A tester other than the Kawasaki Hand Tester should show different readings If a megger or a meter with a large capacity battery is used the ignition coil will be damaged B C 10 20 18 28 Use only Tester 57001 1394 with new battery xIf the tester does not read as specified replace the coil with a new one Spark Plug Removal e Carefully pull the plug caps from the spark plugs e Remove the spark plugs using a suitable plug wrench Spark Plug Installation e Insert the spark plug vertically into the plug hole with the plug installed in the plug wrench e Tighten the plugs Torque Spark Plugs 22 2 2 kgf m 16 ft lb e Fit the plug caps securely e Pull up the spark plug caps lightly to make sure of the installation of the spark plug caps Spark Plug Cleaning and Inspection e Refer to the Spark Plug Cleaning and Inspection in the Periodic Maintenance chapter Spark Plug Gap Inspection e Refer to the Spark Plug Gap Inspection in the Periodic Maintenance chapter TROUBLESHOOTING 10 1 Troubleshooting Table of Contents Engine Troubleshooting Guide pp 10 2 start
67. e grease MoS2 in the assembly of certain engine parts Always check manufacturer recommendations before using such special lubricants 16 Electrical Wires All the electrical wires are either single color or two color and with only a few exceptions must be connected to wires of the same color On any of the two color wires there is a greater amount of one color and a lesser amount of a second color so a two color wire is identified by first the primary color and then the secondary color For example a yellow wire with thin red stripes is referred to as a yellow red wire it would be a red yellow wire if the colors were reversed to make red the main color Wire cross section Color Indicated on the Wire Color Indicated on the Wiring Diagram Yellow Red R 6802060181 17 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 18 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 19 Service Data Service Data terms are defined as follows Standards show dimensions or performances which brand new parts or
68. ead gasket use only the proper gasket The use of a gasket of incorrect thickness will change the compression 3 Valve guides and piston rings rapid carbon accumula tion in the combustion chamber may be caused by worn valve guides and or worn piston oil rings This may be indicated by white exhaust smoke x If the cylinder compression is lower than the MIN check the following 1 Gas leakage around the cylinder head replace the damaged gasket with a new one and check the cylinder head warp Condition of the valve seating Valve clearance Piston cylinder wear piston seizure Piston ring piston ring groove 5 8 ENGINE TOP END Cylinder Head Cylinder Head Assembly Removal e Remove Fan Housing see Flywheel and Stator Coil Removal in the Electrical System chapter Bolt A Lift Hook B e Remove Inlet Manifold see Inlet Manifold Removal in the Fuel System chapter Engine Shroud see Engine Shroud Removal in the Cooling System chapter Spark Plugs see Spark Plug Removal in the Electrical System chapter e Unscrew the rocker cover bolts in the order shown 1 to 5 e Remove the cover A and the gasket e When removing the 1 2 cylinder head set each pis ton at the top dead center T D C A of the compression stroke e Remove Rocker Arm see Valve Mechanism Removal Installa tion Push Rod see Push Rod Removal Rocker Arm Bracket see Valve Mechanism Removal In stallation
69. ed air cleaner Clean or replace eloo high fuel level in float Adjust bowl eWorn piston piston rings Replace eStuck piston rings Clean or replace eWorn cylinder bore Bore or replace eLoose of cylinder head Retighten bolt eFaulty contact of valve Lap seat ePlunge up by valve Adjust valve clearance eWarped cylinder head Replace Broken valve spring Replace eStuck valve Clean or replace eBurned head gasket Replace Check carburetor eCheck for plugged fuel line eCheck for plugged air passage eCheck float level eCheck carburetor setting 1021458 TROUBLESHOOTING 10 3 Engine Troubleshooting Guide Engine power loss Is engine overheated YES e Engine oil level too low Adjust level or add NO Engine oil level too high Adjust level Excessive engine load Decrease load Carburetor not properly adjusted Carbon deposit in combustion chamber Damaged cooling fan Is the ignition spark normal Wrong spark plug Faulty ignition coil Incorrect air gap Engine oil level too low or high Excessively contaminated engine oil Defective oil filter Faulty relief valve Faulty oil pump Clogging oil system Is lubricating condition normal Is unusual smoke emitted out of muffler Plugged air cleaner element Clean or replace Carbon deposit in exhaust hole Clean and muffler Carburetor not properly adjusted Adjust Engine o
70. efe cado du ee 4 2 elei e ge n 4 6 Cooling EandHerrovall ot 4 6 Cooling Fan Inst llatiori n 4 6 Cooling Ear Inspections iaa pedet D to e Met esee 4 6 Engine le e a 4 7 n EnginesShroud Removal rtr aceite tad lotum Ges uius 4 7 Engine Shroud Installation ipt danske theta heen Siac 4 8 4 2 COOLING SYSTEM Exploded View Electric Starter Model Kp020258W5 COOLING SYSTEM 4 3 Exploded View Torque No Fastener Nm itib Remarks 1 Cooling Fan Mounting Bolts 5 9 0 60 52 2 Cooling Fan Screen Screws 3 0 0 31 27 in lb 3 Engine Shroud Bolts 8 8 0 90 78 in lb 4 Housing Bolts 8 8 0 90 78 4 4 COOLING SYSTEM Exploded View Recoil Starter Model Kp020268W5 C Exploded View COOLING SYSTEM 4 5 Torque No Fastener Nem itib Remarks 1 Cooling Fan Plate Mounting Bolts 5 9 0 60 52 2 Engine Shroud Bolts 8 8 0 90 78 in lb 3 Fan Housing Bolts 8 8 0 90 78 in lb 4 Flywheel Bolts 56 5 7 41 4 6 COOLING SYSTEM Cooling Fan Cooling Fan Removal e Refer to the Flywheel and Stator Coil Removal in the Elec trical System chapter Cooling Fan Installation e Refer to the Flywheel and Stator Coil Installation in the Electrical Syst
71. em chapter Cooling Fan Inspection e Remove the fan housing see Flywheel and Stator Coil Removal in the Electrical System chapter e Visually inspect the blades A in the cooling fan If they have any crack warp or damage replace the cool ing fan with a new one any mud or dust have stuck to the cooling fan clean it e Wash the cooling fan in detergent and water CAUTION Do not clean the cooling fan in oil solvent It may be damage by oil solvent Electric Starter Model B Recoil Starter Model C COOLING SYSTEM 4 7 Engine Shroud Engine Shroud Removal Electric Starter Model e Remove Fan Housing see Flywheel and Stator Coil Removal in the Electrical System chapter Lift Hook see Cylinder Head Assembly Removal in the Engine Top End chapter Stator Coil Lead Connector see Regulator Removal in the Electrical System chapter Spark Plug Caps A Engine Shroud Bolts B Engine Shrouds C e Cut off the band A Recoil Starter Model e Remove Fan Housing see Flywheel and Stator Coil Removal in the Electrical System chapter Lift Hook see Cylinder Head Assembly Removal in the Engine Top End chapter Spark Plug Caps A Engine Shroud Bolts B Engine Shrouds C 4 8 COOLING SYSTEM Engine Shroud e Cut off the band A Engine Shroud Installation Electric Starter Model e Install the engine shrouds A e Tighten Torque Engine Shroud Bolts
72. engine and warm up thoroughly e Run the engine at 3 200 r min rpm and read the oil pres sure gauge If the oil pressure is below the specification inspect the oil pump and relief valve see Oil Pump Relief Valve In spection x lf the oil pump and relief valve are not at fault inspect the rest of the lubrication system Cil Pressure 294 to 686 kPa 43 to 99 psi Measurement Condition Engine Oil Temperature 50 60 122 144 F Engine Speed 3 200 r min rpm e Stop the engine e Remove the oil pressure gauge and adapter A WARNING Take care against burns form hot engine oil that will drain through the oil passage when the gauge adapter is removed e Apply a non parmanent locking agent to the oil passage plug and tighten it Torque Passage Plug 3 9 0 40 kgf m 35 in Ib Pump Relief Valve Oil Pump Relief Valve Removal e Remove Crankcase Cover see Crankcase Cover Removal in the Camshaft Crankshaft chapter Governor Shaft see Governor Shaft Removal in the Fuel System chapter Bolts A Pump Cover Plate B e Remove Inner Rotor A Outer Rotor B Spring C Relief Valve Ball D Oil Pump Relief Valve Installation e Fill the rotor housing with engine oil for initial lubrication e Install the outer A and inner rotor B OAlign the inner rotor groove C to the center of the crankcase cover as shown in the figure e Install the relief valve ball and spring
73. ent dry type Governor Flyweight all speed governor Lubrication System Oil Filter Oil Capacity when engine is completely dry Pressure feed by positive displacement pump Cartridge type full flow filter 2 0 L 2 1 US qt Cooling System Forced air cooling by fan Dimensions L x W x FS Models 486 mm x 429 mm x 362 mm 19 1 in x 16 9 in x 14 3 in Dry Weight without muffler FS Models 36 7 kg 80 9 Ib Specifications are subject to change without notice PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart s aoro aep 2 2 Torque arid LOCKING eet ti da oc eoe pe ETI aa 2 3 E A 2 5 iere M O 2 6 Periodic Maintenance Procedures torte 2 7 Esth mEMC 2 7 Low Idle Speed Adjustment pp 2 7 High Idle Speed EE 2 7 Fuel System Cleanliness Inspection Ne 2 8 Element Cleaning and Inspection 2 9 Pa de ats uo oda 2 9 Cylinder C leaning 2 9 Valve Clearance Inspection EE 2 9 Valve Clearance Adj stment rite itta 2 10 Valve Seat de mm 2 11 Valve uu T 2 11 L brication BE NEE 2
74. er Standard 72 98 73 00 mm 2 873 2 874 in Service Limit 73 10 mm 2 878 in Cylinder Bore Out Round Service Limit 0 05 mm 0 002 in KE06122BS1 LUBRICATION SYSTEM 6 1 Lubrication System Table of Contents Exploded VIBW sou Geddes edet 6 2 Engine Oll Flow en E nete tret e tec ud es 6 4 Specification S 6 5 TOONS EE 6 6 Engine Oll and E atu tfe ee 6 7 Engine Oil Level Inspection pr rea tere ter einn e x eb 6 7 EEN 6 7 Oil Filter Removal dede ome altae Oil Filter R bed ants Pressurized Lubrication System pp CI Pressure MeasuremeNi uuu Oil Pump Relief Valye pp Oil Pump Relief Valve Ereegnes EE 6 9 Oil Pump Relief Valve 6 9 Oil Pump Relief Valve creen erect enitn 6 9 ES 6 11 Oil Screen Removal u 6 11 nstallatlOfi erret peti ee EE c t eese rb pepulit dace e 6 11 Cleaning and InspectlOr iier e teen e terea ce ex 6 11 6 2 LUBRICATION SYSTEM Exploded View LUBRICATION SYSTEM 6 3 Exploded View No Fastener pone
75. er Motor Troubleshooting Guide pp 10 6 10 2 TROUBLESHOOTING Engine Troubleshooting Guide If the engine malfunctions check if the way the engine is used is correct If the engine malfunc tions even if the engine is used correctly systematically carry out troubleshooting starting with simple points This chart describes typical troubleshooting procedures Do not unnecessarily disassemble the carburetor the magneto or the engine unless it has been found to be the cause of malfunctioning Engine hard to start Remove spark plug and Are sparks produced check spark by cranking when spark plug is YES gt Faulty spark plug Replace engine while having the replaced plug touched against NO engine block A WARNING sparks produced YES gt Faulty ignition coil Replace Keep the plug as far away when ignition coil is as possible from the plug replaced hole NO elncorrect air gap Correct To avoid an electric shock Faulty flywheel Replace do not hold the plug itself Make sure to hold the plug cap No fuel in the tank Add eEntry of dust or air into Clean fuel hose or filter ePlugged air hole in tank Clean cap and fuel pump Plugged fuel line Clean Make starting attempts a number of times and then remove spark plug and observe electrodes Are they wet Is compression sufficient Excessive use of choke Remove the plug and turn the crankshaft without loading ePlugg
76. ey can be installed in their original positions during assembly Camshaft Tappet Installation e Apply engine oil to the followings Tappet Journal Camshaft Journal Cam Lobe Surface Camshaft Gear e Align the punch marks A on the crankshaft gear and camshaft gear e Install the removed parts see appropriate chapters Camshaft Disassembly e Remove Governor Assembly see Governor Assembly Removal in the Fuel System chapter Spring A ODo not remove the ACR automatic compression release weight B CAMSHAFT CRANKSHAFT 7 15 Camshaft Tappet Camshaft Assembly e Install the governor assembly see Governor Assembly Installation in the Fuel System chapter e After assembling the camshaft check the following items OThe governor plate A must move freely OWhile shaking the camshaft check if the ACR weight B swings smoothly Camshaft Inspection e Check the camshaft gear A for pitting fatigue cracks burrs or any evidence of improper tooth contact x Replace the camshaft with a new one if necessary e Check the top of the cam lobes B for wear burrs or un even contact x Replace the camshaft with a new one if necessary Camshaft Bearing Journal Wear e Measure the height A of each cam lobe the cam height is less than the service limit for either lobe replace the camshaft with a new one Cam Lobe Height Service Limit Inlet 29 62 mm 1 166 in
77. h oil level NO Worn valve stem and valve guide Oil leakage along governor shaft Oil leakage from oil seal Oil leakage from mounting surface Oil leakage from drain bolt Clogged breather valve Drain back hole breather chamber plugged Incorrect oil viscosity Worn piston rings Stuck piston rings Worn cylinder bore Broken piston ring Engine backfires Loose carburetor or inlet manifold loose cylinder head bolt or leaking head gasket Burned or sticking inlet valve Faulty ignition coil Carburetor not properly adjusted Engine knocks Stale fuel Change Excessive carbon deposit in Clean engine Excessive engine load Adjust Engine overheating See Engine power loss Faulty ignition coil Replace KI02147B 10 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 A WARNING ment during test Engine may be cranked in this test Do not touch any rotating parts of engine and equip CAUTION If starter does not stop by engine switch OFF disconnect negative cable from battery as soon as possible Starter does not rotate NO Faulty battery Charge or replace Faulty leads or connection or replace Melted fuse Faulty engine switch Repair o
78. he marks A face out OThoroughly pack high temperature grease to 6096 volume into the space B between the dust lip C and seal lip D Press in the new oil seal using a press or suitable tools until it is flush with flange surface E or maximum 1 mm 0 04 in F lower than the flange surface Do not damage the seal lip PTO Side G KG04093BSi C e When replacing the oil seal A of the governor shaft note the following OApply mineral oil to the lip surface of the governor shaft oil seal Olnstall the oil seal into the crankcase cover B with a suitable tool after inserted the governor shaft C in the crankcase cover and so that the marks D face out Do not damage the seal lip OThe depth is 0 2 mm 0 0 08 in E e Install the governor shaft and plate see Governor Shaft Installation in the Fuel System chapter e Install the crankcase cover see Crankcase Cover Instal lation KG04092BSi C Crankcase Cover Installation e Align the inner rotor groove to the center of the crankcase cover see Oil Pump Relief Valve Installation in the Lu brication System chapter e Apply liquid gasket A to the mating surface of the crankcase cover Sealant Gasket Liquid TB1217H 92104 7001 NOTE OMake the application finish within 5 minutes when the liquid gasket to the mating surface of the crankcase cover is applied OMoreover fit the case and tighten the cover bolts just after finish
79. he operating range CAUTION Do not add more oil above the operating range Ex cess oil will cause a smoking condition OUse the same type and make of oil that is already in the engine NOTE Olf the engine oil type and make are unknown use any brand of the specified oil to top up the level in preference to running the engine with the oil level low Then at your earliest convenience change the oil completely If the oil level is FULL range F drain the excess oil by loosening the drain plug Engine Oil Change e Change the oil after first 8 hours of operation Thereafter change oil every 100 hours e Start and warm up the engine to drain the oil easily e Stop the engine e Place the engine on a level surface e Place a suitable container under the engine e Remove the oil drain plug A and drain the oil WARNING Be careful of hot oil when draining It may be hot enough to burn you severely e Replace the O ring B with a new one Apply grease to the O ring e Install the oil drain plug with the O ring and tighten it Torque Engine Oil Drain Plug 6 9 N m 0 70 kgf m 61 in Ib PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures e Remove the oil filler cap and pour in the specified type and the amount of oil lt Ambient Temperature gt Engine Oil 200 100 00 100 200 300 40 Grade SJ or higher class Viscosity
80. he valve stem to avoid damaging the stem seal e Check to see that the valve moves smoothly up and down in the guide e Check to see that the valve seats properly in the valve seat A If it does not repair the valve seat see Valve Seat Repair in the Periodic Maintenance chapter e Valve installation is the reverse of removal e Install the cylinder head assembly see Cylinder Head As sembly Installation e Set the each piston at T D C of the compression stroke see Cylinder Head Assembly Installation ENGINE TOP END 5 11 5 12 ENGINE TOP END Cylinder Head e Install the rocker arm brackets A so that bracket hollows B fit to the cylinder head projections C e Apply a non permanent locking agent to the rocker arm bracket bolts and tighten them Torque Rocker Arm Bracket Bolts 14 7 1 5 kgf m 11 ft Ib e Install the push rods see Push Rod Installation e Position the rocker arm A so that the hollow side B faces push rod e Apply engine oil to the collars A e For 1 cylinder insert the collars in to the rocker arm hole so that the flatten side B faces PTO side e Insert the washers C onto the valve clearance adjusting bolts D and install them from the flywheel side hole of the rocker arms OAlign the flatten surface of the collars with the flatten sur face E of the valve clearance adjusting bolts e For 2 cylinder insert the collars in to the rocker arm hole
81. idth Service Limit 19 00 mm 0 748 in KG06035BS1 KG06036BS1 CAMSHAFT CRANKSHAFT 7 19 Crankshaft Connecting Rod e Measure the crankpin width A with a dial caliper the crankpin width is more than the service limit replace the crankshaft with a new one Crankpin Width Service Limit 40 0 mm 1 57 in Connecting Rod Big End Bearing Crankpin Wear e Apply a light film of engine oil on the threads of the cap bolts e Install the cap bolts and tighten the bolts to the speci fied torque see Piston Installation in the Engine Top End chapter e Measure the inside diameter A of big end at several points with a telescoping gauge or inside micrometer the inside diameter is more than the service limit re place the connecting rod with a new one Connecting Rod Big End Inside Diameter Service Limit 38 04 mm 1 50 in e Measure the crankpin outside diameter A OUse a micrometer to measure several points around the crankpin circumference xIf the crankpin diameter is less than the service limit re place the crankshaft with a new one Crankpin Outside Diameter Service Limit 37 94 mm 1 49 in Crankshaft Runout e Measure the crankshaft runout OSet the crankshaft in a flywheel alignment jig A or on V blocks gauge OSet a dial gauge B against both bearing journals OTurn the crankshaft slowly to measure the runout The dif ference
82. il level too high Adjust level Worn piston piston rings Replace Worn cylinder bore Bore or replace NO gt See Engine hard to start Is compression sufficient Engine runs erratically Problem in the engine Spark plug fouled pitted or Replace or adjust rotation gapped incorrectly Problem in the fuel system Entry of dust or water into fuel Clean lack of fuel hose or fuel filter Air or vapor lock in fuel line Clean Plugged air vent of fuel tank cap Clean Plugged air fuel passes in Clean carburetor Carburetor not properly adjusted Adjust Carburetor flange leaking at Retighten or replace gasket Worn carburetor body and Replace throttle shaft KI02146B 10 4 TROUBLESHOOTING Engine Troubleshooting Guide Incorrect governor linkage Correct adjustment Faulty governor spring Replace Governor assy malfunctioning Check Problem in the governor system Engine malfunctions at high speed Is revolution fluctuation of Plugged air hole in tank cap Clean relatively large period produced YES Entry of dust and air into fuel Clean filter or fuel pipe when a load is applied Engine malfunctions at low speed Remove spark plug and check Faulty plug insulation Replace spark by cranking engine while Fouled electrodes Clean having the plug touched against Faulty ignition coil Replace engine block Incorrect air gap Cor
83. in position e Install the pump cover plate e Tighten Torque Oil Pump Cover Plate Bolts 5 9 N m 0 60 kgf m 52 in Ib Oil Pump Relief Valve Inspection e Remove the pump cover plate see Oil Pump Relief Valve Removal e Visually inspect the pump gear outer and inner rotor and cover plate xIf there is any damage or uneven wear replace them with new ones OCheck the clearance A between the inner and outer rotor with a feeler gauge Measure the clearance between the high point of the inner rotor and the high point of the outer rotor the measurement exceed the service limit replace the rotors as a set with new ones Inner and Outer Rotor Clearance Service Limit 0 2 mm 0 008 in LUBRICATION SYSTEM 6 9 6 10 LUBRICATION SYSTEM Pump Relief Valve e Measure the outside diameter A of the outer rotor with a micrometer at several points x lf the rotor diameter is less than the service limit replace both the inner and outer rotor with new ones Outer Rotor Outside Diameter Service Limit 52 31 mm 2 059 in e Measure the thickness B of the outer rotor with a mi crometer at several points If the rotor thickness is less than the service limit replace both the inner and outer rotor with new ones Outer Rotor Thickness Service Limit 14 91 mm 0 5870 in e Measure the inside diameter A of the pump housing with a inside micrometer at several points the
84. ing the application of the liquid gasket 04091851 C 7 8 CAMSHAFT CRANKSHAFT Crankcase e Check to see that the dowel pins A O rings B and plas tic pipe C are in place on the crankcase e Install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence as shown in the figure Torque Crankcase Cover Bolts 27 4 2 8 kgf m 20 ft Ib not turn one screw down completely before the others as it may cause the crankcase cover to warp e Install the removed parts see appropriate chapters Crankcase Cover Inspection e Measure the inside diameter A of the crankshaft journal bearing on the crankcase cover at several points place the crankcase cover if the inside diameter is more than the service limit Crankshaft Journal Bearing Inside Diameter Service Limit 38 10 mm 1 500 in Crankcase Disassembly e Remove Crankcase Cover see Crankcase Cover Removal Camshaft and Tappets see Camshaft Tappet Removal Crankshaft see Crankshaft Removal e Pry the crankshaft oil seal A with the suitable tool and remove it Crankcase Assembly e Remove the old gasket from the mating surfaces of the crankcase and cover e Using compressed air blow out the oil passage in the crankcase e With a high flash point solvent clean off the mating sur faces of the crankcase and the cover and wipe them dry Clean the crankcase an
85. inside diameter is more than the service limit re place the crankcase cover with a new one Pump Housing Inside Diameter Service Limit 52 72 mm 2 076 in e Measure the depth B of the pump housing with a depth micrometer at several points any of measurement is more than the service limit re place the crankcase cover with a new one Pump Housing Depth Service Limit 15 16 mm 0 5968 in e Visually inspect the relief valve spring steel ball and valve seat in the crankcase cover If any rough spot is found during above inspection wash the valve clean with a high flash point solvent and blow out any foreign particles on the valve with compressed air WARNING Clean the parts in a well ventilated area and take care that there is no spark or flame anywhere near the working areas Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents If cleaning does not solve the problem replace the relief valve parts with new ones If necessary put the ball in position and lightly tap the ball with a suitable tool to form a perfect seat Measure the free length A of the spring with a vernier caliper x lf the free length of the spring is less than the service limit replace the spring with a new one Relief Valve Spring Free Length Service Limit 20 4 mm 0 803 in LUBRICATION SYSTEM 6 11 Screen Oil Screen Removal e Remove the
86. ll between the piston and cylinder and damage the crankshaft bearings e Scrape the carbon off the piston head e Use the scraping tools A carefully Do not gouge the pis ton head To avoid gouging use scrapers that are made of a material that will not cause damage ENGINE TOP END 5 19 6125852 6037851 5 20 ENGINE TOP END Cylinder Piston e Clean the piston ring grooves A with a broken piston ring or other suitable tools CAUTION Be careful not to widen the ring grooves Damaged ring grooves will require piston replacement Piston Ring and Ring Groove Wear Clean the piston see Piston Cleaning e Visually inspect the piston rings and ring grooves x If the piston rings are worn unevenly or damaged replace them with new ones the ring grooves are worn unevenly or damaged re place both the piston and the piston rings with new ones e Measure the clearance between the top and second rings and their grooves using a thickness gauge A as shown x lf the piston ring groove clearance is greater than the ser vice limit replace the piston with a new one Piston Ring Groove Clearance Service Limit Top 0 12 mm 0 0047 in Second 0 12 mm 0 0047 in NOTE OThe oil ring is a three piece assembled ring It is difficult to measure the ring groove clearance and thickness visually inspect only e Measure the piston ring thickness A OUse a mi
87. lug Cap B Bolts C Stop Switch Lead Connector D Ignition Coil 1 E Ignition Coil 2 F Electric Starter Model G Recoil Starter Model H ELECTRICAL SYSTEM 9 21 9 22 ELECTRICAL SYSTEM Ignition System Ignition Coil Installation e Install the ignition coil on the crankcase so that the stop switch lead connector A face the upward and tighten bolt B first then tighten bolt C While tightening bolts adjust the air gaps to specified gap value as shown D between left leg of ignition coil and left pole plate of magnet E between center of ignition coil and right pole plate of magnet Ignition Coil Air Gap Standard 0 2 0 4 0 008 0 016 in Torque Ignition Coil Bolts 5 9 0 60 kgf m 52 in Ib Ignition Coil Stud Bolts 5 9 N m 0 60 kgf m 52 in Ib Recoil Starter Model NOTE the above procedure to insure proper coil air gap e Fit the ignition coil leads A to the each engine shroud groove B e Install the spark plug cap C Electric Starter Model e Attach the solenoid valve connector lead A and stop switch lead B to the ignition coil lead C with the band D Recoil Starter Model e Attach the stop switch lead A to the ignition coil lead B with the band C Ignition System Ignition Coil Inspection e Remove the ignition coil see Ignition Coil Removal e Measure the winding resistance as follows OSet the han
88. m Governor Assembly Installation e Fit the snap ring into the groove securely e Turn the governor plate by hand and check that the steel balls and governor plate operate freely e Replace the spring pin A with a new one e Be sure to install the washer B and pin 2 0 2 3 mm 0 079 0 091 in C Governor Assembly Inspection e Visually check all governor parts for wear or damage lf any parts are worn or damaged replace them with new ones Governor Shaft Removal e Remove the crankcase cover see Crankcase Cover Re moval in the Camshaft Crankcase chapter e Unscrew the governor shaft plate screws A and remove the governor shaft plate B Pull out the governor shaft C outside NOTE ORemove the governor shaft only if the replacement of the governor shaft is necessary e Replace the oil seal with a new one if the lip shows signs of leakage or it has been damaged see Crankcase Cover Assembly in the Camshaft Crankshaft chapter Governor Shaft Installation e Apply engine oil to the governor shaft e Insert the governor shaft A into the crankcase cover e Install the governor shaft plate B to the shaft e Tighten Torque Governor Shaft Plate Screws C 2 0 0 20 kgf m 18 in Ib e Check that the governor shaft moves freely in its operating range NOTE Olf the oil seal is removed oil seal is put on after shaft is installed see Crankcase Cover Installation in
89. meter Cylinder Inside Diameter Cylinder Inside Diameter Out Round 0 35 mm 0 0138 in TIR 0 05 mm 0 002 in 5 95 mm 0 234 in 5 93 mm 0 233 in 6 08 mm 0 239 in 31 0 mm 1 22 in TIR 0 5 mm 0 02 in 10 91 mm 0 430 in 11 13 mm 0 438 in 72 79 mm 2 866 in 0 12 mm 0 0047 in 0 12 mm 0 0047 in 1 1 mm 0 043 in 1 1 mm 0 043 in 0 7 mm 0 028 in 0 9 mm 0 035 in 1 05 mm 0 041 in 15 96 mm 0 628 in 16 08 mm 0 633 in 16 05 mm 0 632 in 73 10 mm 2 878 in 0 05 mm 0 002 in 2 was WH Specifications ENGINE TOP END 5 5 Item Standard Valve Clearance Inlet Exhaust Valve Seating Surface Angle Inlet Exhaust Valve Seating Surface Width Inlet Exhaust Valves Guide Inside Diameter Inlet Exhaust Cylinder Inside Diameter 0 10 0 15 mm 0 0039 0 059 in 45 0 8 1 4 mm 0 031 0 055 in 0 8 1 4 mm 0 031 0 055 in 6 000 6 012 mm 0 2362 0 2367 in 72 98 73 00 mm 2 873 2 874 in 5 6 ENGINE TOP END Special Tools Piston Ring Pliers 57001 115 7570115ST Compression Gauge 20 kgf cm 57001 221 Piston Ring Compressor Grip 57001 1095 7570221ST 5157109551 Piston Ring Compressor Belt 67 79 57001 1097 7571097ST Compression Gauge Adapter M14 x 1 25 57001 1159 875711595 ENGINE
90. must not be used for other B ZA 2 Do not drop or hit the valve seat cutter or the diamond particles may fall off NU AS N 3 Do not fail to apply engine oil to the valve seat cutter NS before grinding the seat surface Also wash off ground lt 22 particles sticking to the cutter with washing oil C 7 ODo not use a wire brush to remove the metal particles from the cutter It will take off the diamond particles KM07019BS1 4 Setting the valve seat cutter holder A in position op erate the cutter B with one hand C Do not apply too much force to the diamond portion NOTE OPrior to grinding apply engine oil to the cutter and dur ing the operation wash off any ground particles sticking to the cutter with washing 5 After use wash the cutter with washing oil and apply a thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter represent the following 32 Cutter angle A 37 5 Cutter diameter B KS8B Manufactured lot number KE05016BS1 Operating Procedures e Clean the seat area carefully e Recondition the valve seats with the valve seat cutters 45 329 and lap the valves Check the seats for good contact all the way around with 4 A machinist s dye e Measure the seat width A If it is more than the standard width the seating surface should be refaced
91. n or plastic mallet if necessary to loosen the crankshaft Crankshaft Installation e Clean up the crankshaft and crankcase thoroughly espe cially at the bearing contact surfaces e Pack some amount of high temperature grease into the oil seals on the crankcase e Apply engine oil to the crankshaft journal e Apply molybdenum disulfide oil solution to the crankpin OThe molybdenum disulfide oil solution is a mixture of en gine oil and molybdenum disulfide grease with a weight ratio 10 1 e Carefully insert the crankshaft end into the main bearing in the crankcase Cleaning Inspection e After removing clean the crankshaft and the connecting rods with a high flash point solvent and dry them with compressed air e Inspect the teeth of the crankshaft gear for pitting fatigue cracks burrs and any evidence of improper tooth contact the crankshaft with a new one if necessary e Inspect the crankshaft and connecting rods especially at the bearing surfaces for wear scratches any evidence of improper contact or other damages them with new ones if necessary 7 18 CAMSHAFT CRANKSHAFT Crankshaft Connecting Rod Connecting Rod Bend Twist e Measure the connecting rod bend OSelect an arbor A of the same diameter as the connect ing rod big end and insert the arbor through the connect ing rod big end OSelect an arbor of the same diameter as the piston pin and at least 100 mm 3 94 in
92. nkpin Width Wear ssssssssssseessssrnneeesnnesrrresstrrnneernnnnsnnresene 7 18 Connecting Rod Big End Bearing Crankpin Wear sssssessssssreresrrerssrrrnerrrnneernnrrsnnrnsene 7 19 Crankshaft le ie 7 19 Crankshaft Main Journal Wear 0 00 0000 7 20 7 2 CAMSHAFT CRANKSHAFT Exploded View CAMSHAFT CRANKSHAFT 7 3 Exploded View No Fastener Remarks kgf m ft Ib 1 Breather Chamber Cover Bolts 5 9 0 60 52 in lb 2 Breather Valve Mounting Screw 2 0 0 20 18 in lb 3 Connecting Rod Big End Cap Bolts 9 8 1 0 87 in lb EO 4 Crankcase Cover Bolts 27 4 2 8 20 S 5 Crankcase Cover Oil Passage Plugs 3 9 0 40 35 in lb L 6 Crankcase Oil Passage Plugs L EO Apply engine oil G Apply grease L Apply a non parmanent locking agent Mi Apply mineral oil MO Apply molybdenum disulfide oil R Replacement Parts S Tighten the fasteners following the specified sequence 7 4 CAMSHAFT CRANKSHAFT Specifications Item Camshaft Tappet Cam Lobe Height Inlet Exhaust Camshaft Journal Diameter PTO Side Flywheel Side Camshaft Bearing Inside Diameter Crankcase Crankcase Cover Service Limit 29 62 mm 1 166 in 29 62 mm 1 166 in 15 99 mm 0 630 in 15 99 mm 0 630 in 16 14 mm 0 635 in 16 14 mm 0 635 in Crankshaft Connecting Rod Connecting Rod Bend Connecting Ro
93. odel Note Portion surrounded by shows procurement parts park Plugs Carburetor Starter lt Sa NY a zw 2 7 eT Ss 18 XS Color Code Battery m or START E pi KH040418W4 C ELECTRICAL SYSTEM 9 9 Wiring Dagram Recoil Starter Model Note Portion surrounded by shows procurement parts park Plugs F Ee Color Code BK Black KH040428W4 9 10 ELECTRICAL SYSTEM Precautions There are a number of important precautions that you must follow when servicing electrical systems Learn and observe all the rules below ODo not reverse the battery cable connections This will burn out the diodes in the electrical parts OAlways check the battery condition before judging other parts of the electrical system A fully charged battery is necessary for conducting accurate electrical system tests ODo not hit the electric parts with a hammer or do not drop the electric parts These may result in the electric parts damage or breakage OTo prevent damage to electrical parts do not disconnect the battery cables or any other electrical connections when the engine switch is on or while the engine is running OBecause of the large amount of current never keep the engine switch turned to the start position when the starter motor will not start o
94. odel D Recoil Starter Model E Governor Arm Removal e Remove the inlet pipe see Inlet Pipe Removal e Unhook the throttle link spring A and throttle link rod B from the throttle shaft lever C while pull off the carbure tor e Loosen the clamp nut A and take off the governor arm B 3 10 FUEL SYSTEM Governor Link Mechanism Governor Arm Installation e Install the governor arm A onto the governor shaft B temporarily e Be sure the link spring C around the throttle link rod D is in place and that it pulls the governor arm and throttle lever E toward each other e Turn the top end of the governor arm counterclockwise F to fully open the carburetor G throttle valve and hold it there e Turn the governor shaft counterclockwise fully turn the shaft to end of its travel e Tighten the clamp nut H Torque Governor Arm Clamp Nut 7 8 0 80 kgf m 69 in Ib 6 mm 0 24 in I View from Bottom J e Install Inlet Pipe see Inlet Pipe Installation Control Panel Assembly see Control Panel Assembly Installation Governor Assembly Removal e Remove Camshaft see Camshaft Tappet Removal in the Camshaft Crankshaft chapter Pin A Washer 30 B Snap Rings C Washer 42 D Sleeve E Governor Plate F Steel Balls G Ball Guide H Ball Plate 1 KC04054BS3 04052852 FUEL SYSTEM 3 11 Governor Link Mechanis
95. 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 and Cotter Pin When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more Install the circlip with its chamfered side facing load side as well Replace any circlips retaining rings and cotter pins that were removed with new ones as re moval weakens and deforms them If old ones are reused they could become detached while running leading to a problem 15 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film During assembly oil or grease whichever is more suitable should be applied to any rubbing surface which has lost its lubricative film Old grease and dirty oil should be cleaned off Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles Don t use just any oil or grease Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended This manual makes reference to molybdenum disulfid
96. 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 any where near the working area this includes any ap pliance with a pilot light Do not use gasoline or a low flash point solvent to clean the cylinder head A fire or explosion could result Valve Clearance Inspection NOTE OValve clearance must be checked when the engine is cold at room temperature e Remove the rocker covers see Cylinder Head Assembly Removal in the Engine Top End chapter e Place the piston at the top dead center TDC of the com pression stroke by turning the crankshaft clockwise facing the flywheel PERIODIC MAINTENANCE 2 9 2 10 PERIODIC MAINTENANCE Periodic Maintenance Procedures No 1 Cylinder OThe left projection A on the flywheel is faced with the right leg B on the 1 ignition coil C as shown in the figure OCheck the inlet and exhaust valves are closed completely if not turn the flywheel one turn 360 clockwise and face the left projection with the right leg again No 2 Cylinder OThe left projection A on the flywheel is faced with the right leg B on the 2 ignition coil C as shown in the figure Follow No 1 cylinder alignment e Then check the valve clearance OUsing a thickness gauge A measure the valve clearance between the rocker arm B and the valve stem end
97. on e Carefully pull the plug cap from the spark plug and re move the spark plug the plug is oily or has carbon built up on it clean the plug using a high flash point solvent and a wire brush or other suitable tools the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug with a new one Use the standard spark plug or its equivalent Insulator A Center Electrode B Plug Gap C Side Electrode D Spark Plug Gap Inspection e Measure the gap with a wire type thickness gauge If the gap is not correct carefully bend the side electrode with a suitable tool to obtain the correct gap Spark Plug Gap Standard 0 7 0 8 mm 0 028 0 031 in 79 9 9 0 9 9 9 0 0 ANS ASY SSS lt NNN SSS 222 YS KZ gt il Be ws 8 10012351 FUEL SYSTEM 3 1 Fuel System Table of Contents Exploded VIEW uasa e bo C def cate e 3 2 EN 3 6 Governor Link ode sot ae toi deae ea 3 8 Control Panel Assembly Removal pp 3 8 Control Panel Assembly Installation pp 3 8 Governor Arm Removal aeree t detur Fa exp Puit eve a etuer dE 3 9 Governor Arm Installation a eve 3 10 Governor Assembly
98. r replace YES Faulty solenoid switch Replace Is click sound from solenoid switch Weak battery or replace Faulty leads or connection or replace Solenoid to motor Faulty solenoid switch Replace Main terminal in solenoid Faulty starter motor or replace Starter rotates but slow Is Ew normal and well e Weak battery Weak battery Charge or replace Ew Faulty leads or connection Repair or replace Solenoid to motor Faulty solenoid switch Replace Main terminal in solenoid Faulty starter motor or replace Faulty engine Repair or replace Starter rotates but engine can not crank Does pinion mesh with ring NO Worn pinion or ring gear Incorrect starter alignment Correct YES I Replace or replace Faulty pinion clutch Faulty engine Starter does not stop in engine switch OFF Can stop starter by engine NO Faulty engine switch or replace switch OFF Faulty solenoid switch YES Faulty pinion or ring gear Repair or replace Incorrect starter alignment Faulty pinion return or replace mechanism KI03022B Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99
99. r the current may burn out the starter motor windings OTake care not to short the leads that are directly con nected to the battery positive terminal to the chassis ground OTroubles may involve one or all items in some cases Never replace a defective part without determining what CAUSED the failure If the failure was occurred by an other item or some other items repair and or replace the item s Or the failure may happen again OMake sure all connectors in the circuit are clean and tight and examine the leads for signs of burning fraying etc Poor leads and bad connections will affect electrical sys tem operation OMeasure the coil and the winding resistance when the parts are cold at room temperature OElectrical connectors Connectors A Connectors B 8 07000251 8 07000351 ELECTRICAL SYSTEM 9 11 Charging System Flywheel and Stator Coil Removal Electric Starter Model e Remove Element Assembly see Element Removal in the Fuel System chapter Fuel Pump see Fuel Pump Removal in the Fuel System chapter Stator Coil Lead Connector see Regulator Removal Screw Rivets A and Guard B e Remove Screws A and Screen B Spacer e Remove Bolts A Fan Housing B e Remove Ignition Coils A see Ignition Coil Removal Bolts B Cooling Fan C e Hold the flywheel with a suitable tool A remove the fly wheel bolt B and washer 9 12 EL
100. rankcase Then it is led to the air cleaner Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase and then returned back to the bottom of crankcase 2 Exhaust Emission Control System The exhaust emission control system applied to this engine consists of a carburetor and an ignition system having optimum ignition timing characteristics The carburetor has been calibrated to provide lean air fuel mixture characteristics and opti mum fuel economy with a suitable air cleaner and exhaust system TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED Federal law and California State law prohibits the following acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new engine for the purpose of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the engine after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Do not tamper with the original emission related part e Carburetor and internal parts e Spark plugs e Magneto or electronic ignition system e Fuel filter element e Air cleaner elements e Crankcase e Cylinder heads e Breather chamber and internal parts e Inle
101. rect WARNING Keep the plug as far away as possible from the plug hole To avoid an electric shock do not hold the plug itself Make sure to hold the plug cap Is unusual smoke emitted out of YES Overrich fuel in pilot system Turn in pilot screw by muffler NO a minor extent Directly and gradually open YES Plugged in carburetor interior Disassemble and throttle valve by hand Does the clean revolution drop or does engine NO stall at a certain position Is air sucked through carburetor Loose flange nuts Retighten flange M Damaged gasket Replace Are valve clearances of normal NO Compression leakage Adjust valve clearance values Wrong valve timing Correct alignment of YES timing gear marks Is alignment of timing gear NO Largely deviated valve timing Correct alignment of marks correct timing gear marks K102026B TROUBLESHOOTING 10 5 Engine Troubleshooting Guide Fuel consumption is excessive Is compression sufficient YES High fuel level in carburetor float chamber including overflow NO High idling RPM Choke partially closed Worn piston piston rings Stuck piston Worn cylinder bore Loose of cylinder head bolt Faulty valve seat contact Plunge up of valve Wrong valve timing Broken valve spring Stuck valve Cil consumption is excessive Is compression sufficient YES Plugged oil ring groove Hig
102. ric Starter Model only Governor Arm see Governor Arm Removal in the Fuel System chapter e Unscrew the mounting bolts in the order shown 1 to 10 and remove the crankcase cover from the crankcase OThere are two dowel pins on the crankcase mating surface Using a wooden or plastic mallet gently tap crankcase to loosen the crankcase cover Crankcase Cover Disassembly e Remove Crankcase Cover see Crankcase Cover Removal Governor Shaft see Governor Shaft Removal in the Fuel System chapter Pry the governor shaft oil seal A with the suitable tool and remove it e Pry the crankshaft oil seal A with the suitable tool and remove it CAMSHAFT CRANKSHAFT 7 7 Crankcase Crankcase Cover Assembly e Chip the old gasket from the mating surfaces of the crankcase and cover e Using compressed air blow out the oil passage in the crankcase cover e With a high flash point solvent clean off the mating sur faces of the crankcase and the cover and wipe them dry WARNING Clean the crankcase and cover in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean parts A fire or explosion could result e Be sure to replace the oil seal with a new one if removed OApply mineral oil to the crankshaft oil seal outside Olnstall the oil seal so that t
103. rings A with needle nose pliers B e Remove the piston by pushing the piston pin A to the direction from which the snap ring was removed e Remove the piston from the connecting rod Cylinder Piston e Remove the top and second rings with piston ring pliers Special Tool Piston Ring Pliers 57001 115 e f the special tool is not available carefully spread the ring opening with your thumbs then push up to the opposite side of the ring A to remove it e Remove the 3 piece oil ring with your thumbs in the same manner Piston Installation e Install the expander A in the piston oil ring groove so that the expander ends B touch together never overlap them e Install the upper and lower steel rails There is no UP or Down to the rails They can be installed either way e Do not mix up the top and second rings e Install the second ring as follows Replacing with new one Olnstall the second ring so that the white stripe A is on the right side of the end gap Reassembling the ring in use Olnstall the second ring so that the notched edge B faces upward e Install the top ring e The rings should turn freely in the grooves Piston Head C Top Ring D Second Ring E e Align the piston and rings with the piston ring end gap as shown in the figure Arrow Match Marks A Top Ring End Gap Upper Steel Rail End Gap B 45 C Second Ring End Gap Lower Steel Rail End Gap D ENGINE T
104. rottle shaft lever while pull off the carburetor e Remove the carburetor gaskets and insulator FUEL SYSTEM 3 17 3 18 FUEL SYSTEM Carburetor Carburetor Installation e Clean the mating surface of the carburetor and inlet man ifold e Replace the gaskets A with new ones e Install the insulator B carburetor C and gaskets se quence as shown in the figure e Apply dielectric grease to the solenoid valve connector e Connect the solenoid valve connector Electric Starter Model D Recoil Starter Model E e Install the throttle link rod A and spring B to the throttle shaft lever C NOTE Take care not to bend the throttle link rod during instal lation e Make sure the link spring around the throttle link rod is in place and that it pulls the governor arm and carburetor throttle shaft lever toward each other FUEL SYSTEM 3 19 Carburetor e Install the fuel tube A fully so that the clamp knob B faces the downward e Install the removed parts see appropriate chapters e After installation adjust the idle speed see Low High Idle Speed Adjustment in the Periodic Maintenance chapter Carburetor Disassembly Assembly FS Models e Refer to the illustration shown for disassembly and as sembly e There are several passage plugs ball plugs in the car buretor body Do not remove e Before disassembly mark the out side of choke and throt tle valves for assembling them e
105. s 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 circumference so that it will go into place smoothly 11 Ball Bearing Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary Replace any ball or needle bearings that were removed with new ones Install bearings with the manufacturer and size marks facing out applying pressure evenly with a suitable driver to the end of the race that contacts the press fit portion and press it evenly over the base component 3 GENERAL INFORMATION 1 3 Before Servicing 12 Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally dam ages seals When pressing in a seal which has manufacturer s marks press it in with the marks facing out Seals should be pressed into place using a suitable driver which contacts evenly with the side
106. systems have 1 4 GENERAL INFORMATION Before Servicing Service Limits indicate the usable limits If the measurement shows excessive wear or deteri orated performance replace the damaged parts GENERAL INFORMATION 1 5 Model Identification Electric Starter Model Recoil Starter Model Cylinder Number Designation No 1 Cylinder is the left hand cylinder viewed from the inlet pipe No 2 Oylinder is the right hand cylinder viewed from the inlet pipe 1 6 GENERAL INFORMATION General Specifications Item Type of Engine Cylinder Layout Bore x Stroke Piston Displacement Direction of Rotation Compression Release Low Idle Speed High Idle Speed Ignition System FS481V FS541V FS600V Forced air cooled vertical shaft OHV 4 stroke gasoline engine 90 V Twin 73 mm x 72 mm 2 87 in x 2 84 in 603 cm 36 8 cu in Counterclockwise facing the PTO shaft Automatic compression release 1 550 r min rpm 3 600 r min rpm Transistorized flywheel magneto RFI Per Canada and U S A requirements Starting System FS Models Electric starter Recoil starter Charging System Electric Starter Model Recoil Starter Model 12 V 15 amps with regulator 12 V 3 6 amp without regulator optional part Spark Plug BPR4ES Carburetor FS Models Float type fixed main jet internally vented single barrel Fuel Pump Diaphragm type pulse pump Air Cleaner FS Models Dual stage elem
107. t pipe and tube GENERAL INFORMATION 1 1 General Information Table of Contents Before Servicing pp Model ldentificati Nn General Specifications 1 2 GENERAL INFORMATION Before Servicing Before starting to service the engine carefully read the applicable section to eliminate unnecessary work Photographs diagrams notes cautions warnings and detailed descriptions have been in cluded wherever necessary Nevertheless even a detailed account has limitations a certain amount of basic knowledge is required for successful work Especially note the following 1 Dirt Before removal and disassembly clean the engine Any dirt entering the engine carburetor or other parts will work as an abrasive and shorten the life of engine For the same reason before installing a new part clean off any dust or metal filings 2 Battery Ground Remove the ground lead from the battery before performing any disassembly operations on the equipment This prevents a the possibility of accidentally turning the engine over while partially disassembled b sparks at electrical connections which will occur when they are disconnected c damage to electrical parts Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them evenly in a staggered sequence This is to
108. tch key is 1741 turned to the Run position ANIN KC05200BS1 Low Idle Speed Adjustment e Refer to the Low Idle Speed Adjustment in the Periodic Maintenance chapter High Idle Speed Adjustment e Refer to the High Idle Speed Adjustment in the Periodic Maintenance chapter High Altitude Operation At high altitude the standard carburetor air fuel mixture will be excessively rich Performance will decrease and fuel consumption will increase High altitude performance can be improved by installing a smaller diameter main jet in the carburetor and adjusting the idle speed NOTE OThe main jet high altitude kits are available if the equip ment is to be used in the high altitude The main jet numbers are stamped on the ends of the main jets High Altitude Main Jet Altitude Main Jet No 0 1 000 0 000 ft 102 1 000 2 000 m 3 000 6 000 ft 100 2 000 m 6 000 ft and higher 98 Main Jet Replacement Electric Starter Model Close the fuel shut off valve in the equipment e Remove the carburetor see Carburetor Removal e Unscrew the solenoid valve A and take off the float chamber B and gasket KC05209BS1 Carburetor e Using a properly sized blade screw driver carefully re place the main jet A with a new one for altitude expected e Tighten Torque Main Jet 2 3 0 23 kgf m 20 in Ib e Replace the float chamber gasket with a new one e Install
109. ter Model KH020378W5 C ELECTRICAL SYSTEM 9 3 Exploded View No Fastener Remarks 1 Flywheel Bolt 2 lgnition Coil Bolts 3 Spark Plugs 4 Coil Screws G Apply dielectric grease 9 4 ELECTRICAL SYSTEM Exploded View Recoil Starter Model KH020388W5 C Exploded View ELECTRICAL SYSTEM 9 5 No Fastener Flywheel Bolt Ignition Coil Bolts Ignition Coil Stud Bolts Spark Plugs Stator Coil Screws Torque kgf m ft lb 56 5 7 41 5 9 0 60 52 in lb 22 2 2 16 3 4 0 35 30 Remarks 9 6 ELECTRICAL SYSTEM Specifications Item Charging System Regulated Output Voltage Electric Starter Model only Stator Coil Resistance Electric Starter Model Recoil Starter Model Unregulated Stator Output Electric Starter Model only Regulator Resistance Electric Starter Model only Standard 14 1 V DC 0 1 0 14 Q 44 150 26 34 V AC 3 000 rpm in the text Service Limit 15 V DC 26 V 000 rpm Ignition System Ignition Coil Air Gap Primary Winding Resistance Secondary Winding Resistance Spark Plug Plug Gap 0 2 0 4 mm 0 008 0 016 in in the text in the text BPR4ES 0 7 0 8 mm 0 028 0 031 in ELECTRICAL SYSTEM 9 7 Special Tool Hand Tester 57001 1394 9 8 ELECTRICAL SYSTEM Wiring Dagram Electric Starter M
110. the Camshaft Crankshaft chapter 3 12 FUEL SYSTEM Carburetor Fuel and Air Flow Electric Starter Model The main system of the carburetor consists of the main jet A main nozzle B and the main air passage C main air jet D The main system meters fuel to the engine dur ing moderate to heavy load conditions Fuel flows through the main jet and into the main nozzle where it is joined by air from the main air passage main air jet The resulting mixture flows out the end of the main nozzle into the carbu retor bore where it is atomized by the high speed air flow and carried into the engine The pilot system includes the pilot jet E pilot screw F idle mixture screw pilot air jet G pilot outlet H and the bypass holes I The pilot system meters the fuel air mixture while the engine is idling and running under a light load Under these conditions there is very little air flow through the carburetor bore so little that it is not enough to draw fuel through the main system of the carburetor and atomize it Instead the fuel is drawn through the pilot system since the nearly closed throttle valve J 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
111. the new gasket and float chamber e Tighten the solenoid valve Torque Solenoid Valve 4 5 N m 0 46 kgf m 40 in Ib Recoil Starter Model e Close the fuel shut off valve in the equipment e Remove the carburetor see Carburetor Removal e Unscrew the float chamber mounting screw A and take off the float chamber B and gasket e Using a properly sized blade screw driver carefully re place the main jet A with a new one for altitude expected e Tighten Torque Main Jet 2 3 0 23 kgf m 20 in Ib e Replace the float chamber gasket with a new one e Install the new gasket and float chamber e Tighten the float chamber mounting screw Torque Float Chamber Mounting Screw 4 5 N m 0 46 kgf m 40 in Ib Fuel System Cleanliness Inspection e Refer to the Fuel System Cleanliness Inspection in the Periodic Maintenance chapter FUEL SYSTEM 3 15 3 16 FUEL SYSTEM Carburetor Inlet Pipe Removal Electric Starter Model e Remove Element Assembly see Element Removal Control Panel Assembly see Control Panel Assembly Removal Inlet Pipe Mounting Nut A Ground Lead B Clamp C Breather Hose D Inlet Pipe E Recoil Starter Model e Remove Element Assembly see Element Removal Control Panel Assembly see Control Panel Assembly Removal Inlet Pipe Mounting Nut A Clamp B Breather Hose C Inlet Pipe D Inlet Pipe Installation Electric Starter Model e Replace the gasket A with a new one
112. ts 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 Diameter Torque mm N m kgf m ft lb 4 2 0 0 20 17 in lb 5 3 4 0 35 30 in lb 6 5 9 0 60 52 in lb 8 15 1 5 11 10 20 2 0 15 PERIODIC MAINTENANCE 2 5 Specifications Item Standard Fuel System Idle Speed 1 Low Idle Speed Carburetor idle rpm 1 450 r min rpm Low Idle Speed Governor idle rpm 1 550 r min rpm High Idle Speed 3 600 r min rpm Air Cleaner Type Dual stage filtration system Pre cleaner FS Models Foam element Second stage cleaner FS Models Paper element Engine Top End Valve Clearance Inlet Exhaust 0 10 0 15 mm 0 0039 0 0059 in Valve Seating Surface Angle Inlet Exhaust 45 Valve Seating Surface Width Inlet 0 8 1 4 mm 0 031 0 055 in Exhaust 0 8 1 4 mm 0 031 0 055 in Lubrication System Engine Oil Type SJ or higher class Viscosity SAE 40 SAE 30 SAE 10W 30 SAE 10W 40 or SAE 5W 20 Capacity 1 5 L 1 6 US qt When the oil filter is not removed 1 7 L 1 8 US qt When the oil filter is removed Level Operating range grid area ADD and FULL on dipstick Electrical System Spark Plug NGK BPR4ES Spark Plug Gap 0 7 0 8 mm 0 028 0 031 in 1 Idle speeds may vary depending on each equipment
113. ut Service Limit FS Models 0 043 mm 0 0017 in STARTER SYSTEM 8 9 6211061051 09013851 11060751 KH09014BSi 8 10 STARTER SYSTEM Electric Starter System e Measure the armature winding resistance OSet the multimeter selector switch to the R x 1 O position and check the resistance between each segment and all the others the resistance it too high or even infinite the armature winding has an open circuit Replace the starter motor Armature Winding Resistance Close 0 e Setthe multimeter selector switch to the R x 1 kO position and measure the resistance between the commutator and the armature shaft the resistance is less than infinite the armature is shorted Commutator to Shaft Resistance gt e Test the armature winding for shorts OPlace the armature on a growler A OHold a thin metal strip e g hack saw blade on top of the armature on the growler and rotate the armature one complete turn the metal strip vibrates the windings are internally shorted to each other and the starter motor must be replaced Yoke Assembly Inspection e Setthe multimeter selector switch to the R x 1 kO position and measure the resistance between the positive brushes and stator motor yoke the resistance is less than infinite the positive brush is shorted to ground Replace the yoke assembly Positive Brush to
114. val Installation e Remove Clamp A Fuel Filter B e When install the fuel filter arrow mark C faces fuel pump side P Fuel Filter Inspection e Visually inspect the fuel filter A xIf the filter is clear with no signs of dirt or other contami nation replacement of the fuel filter is not necessary If the filter is dark or looks dirty replace it with a new Also check the rest of the fuel system for contamination 7 10 P 3 26 FUEL SYSTEM Air Cleaner Element Removal FS Models e Open the air cleaner cover A e Loosen the clamp A e Remove the inlet hose B together with the element as sembly C e Loosen the clamp A e Remove Inlet Hose B Foam Element C Element Installation FS Models e Install the form element A to the paper element B e Install the inlet hose A and tighten the clamp B OCheck that the element C is horizontally installed 068157 FUEL SYSTEM 3 27 Air Cleaner e Install the inlet hose A and tighten the clamp B e Close the air cleaner cover A Element Cleaning and Inspection Air cleaner elements are not recommended to be cleaned and each air cleaner element should be replaced with new ones e Refer to the Element Cleaning and Inspection in the Pe riodic Maintenance chapter COOLING SYSTEM 4 1 Cooling System Table of Contents Exploded e bo C d
115. viously 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 2009 Kawasaki Heavy Industries Ltd First Edition 1 May 31 2009 K LIST OF ABBREVIATIONS ABDC AC ATDC BBDC BDC BTDC DC ft ampere s after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree s Celsius direct current farad s degree s Fahrenheit foot feet gram s hour s liter s Ib m min N Pa PS psi rpm TDC TIR lt 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 EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emission 1 and exhaust emission 2 control systems EM in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board 1 Crankcase Emission Control System A sealed type crankcase emission control system is used to eliminate blow by gases The blow by gases are led to the breather chamber through the c
116. wing the tightening se quence as shown in the figure Torque Rocker Cover Bolts 5 9 N m 0 60 kgf m 52 in Ib 5 10 ENGINE TOP END Cylinder Head e Install Spark Plugs see Spark Plug Installation in the Electrical System chapter Engine Shroud see Engine Shroud Installation in the Cooling System chapter Lift Hook A e Tighten Torque Lift Hook Bolt B 5 9 0 60 kgf m 52 e Install the removed parts see appropriate chapter Push Rod Removal e Set each piston at the T D C of the compression stroke e Remove the rocker arm see Valve Mechanism moval Installation Pull out the push rods A NOTE OMark the push rods and rocker arms so they can be installed in their original position during assembly n Push Rod Installation e Set each piston at the T D C of the compression stroke e Apply engine oil to the both ends and shaft of the push rod e Install the push rods in their original positions of the tappet hollow A e Check that both inlet and exhaust push rods on each cylinder are at lowest position on the cam lobes If the piston is not at the T D C of the compression stroke turn the flywheel clockwise one turn 360 and reset each pis ton at the T D C of the compression stroke e Be sure the end of the push rods are correctly seated on the tappets e Install the rocker arm see Valve Mechanism Removal In stallation e Check and adjust the valve cle
117. 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 WARNING Clean 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 7 10 CAMSHAFT CRANKSHAFT Breather The function of the breather is to create a negative pressure in the crankcase which prevents oil from being forced out of the engine through the piston rings oil seals or gaskets A sealed type crankcase emission control system is used to prevent blow by gases from emitting in the air The blow by gases are led to the breather chamber through the crankcase and camshaft Then it is drawn into the clean side of the air cleaner through the cylinder head and hose and mixed with the clean air flow and subsequently comes into the combustion chamber through the carburetor and inlet 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 Electric Starter Model 1 L7 CR ri lt S LE rarer 1 gt WW Fresh Air 22 Blow by Gas K6080358W4

4-Stroke Air-Cooled V-Twin Gasoline Engine Service Manual

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