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Service Manual - CKC Civil Construction Equipment

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1. 20224 48075 920554 11009 220 J920564 B 32059 92200 y Y 1308 14024 16115 066 c 21178 H 130 go 203 311 491104 i amp N Q o20090 9160354 isis 50 d 16035 200338 482 d ao1zo a 920094 92 2011 a L 92170 A 2016 12011 8 1 92015 gt Bao O 13183 amp 92015 11010 4 1 12 GENERAL INFORMATION Exploded View FE350 16171 Be A A LS Q 16115 92055A 6 59226 233 92200 ho 49110 4 311 203 560306 56030 1 260114 1704 920098 o L Q f N Y E 3 e a g H E G S z z NT 2 ss y E o fd o s 22 o ei 3 bi 4 o Se SS 5 gt 7 H o a S L 921504 920498 92015 41010 no gt FE 05 W5 C SERVICE DATA 2 1 Service Data Table of Contents Service Specifications as 2 2 AGjUSIMENt SPECICATION 2 did 2 8 Tightening tele HE ee re 2 9 Wiring Diagram ssadst did dd dada 2 10 Troubleshooting sacir ate 2 2 aie ida dia 2 12 Starter Motor Troubleshooting and Actons nenn nnernnnn rennen nennen 2 17 Disassembly Sequence FE120 Hp a steet e eier mens lee kauen 2 18 Disassembly Sequence FE250 290 350 4001 2 19 2 2 SERVICE DATA Service Specifications Service Limit mm Item FE120 FE170 FE250 Type D
2. FES153S1 3 50 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Lubrication System FE311552 Oil Level Sensor Switch If the oil level becomes lower than the preset value the sensor switch A closes As a result the base current IB1 passes through the Zener diode Z1 and the resistor R12 to flow to TR1 to maintain the circuit The base current IB1 is held by the amplified collector current IC1 and as a result the spark current does not generate causing the engine to stop Refer to the section on Ignition System for comparison A Oil Level Sensor Switch ESW Engine Switch FE311682 Inspection method e Verify that the oil level of the engine is normal e Disconnect the wire from the oil level sensor terminal e Set the measurement range of the tester to R x 1 Q and connect one of the tester leads to the terminal of the sensor and the other end to ground The tester should read oo x If the tester does not read oo the oil level sensor switch is faulty e Gently lift the PTO side to tilt the engine DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 51 Lubrication System e When the engine is tilted to a certain angle the tester should read 0 Q If the tester does not read 0 2 but remains at o the oil level sensor switch is faulty A Terminal B O ring C Clamp D Oil Level Sensor Switch Igniter with oil level warning light Inspection separate type
3. FE313551 Flush FES13681 FE313851 FES13981 3 60 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Balancer Balancer Shaft Journal Diameter Service Limit minimum PTO Side Flywheel Side FE170 14 943 mm 0 5883 in 14 933 mm 0 5879 in Xx If the measured value is smaller than the service limit replace the balancer shaft X For details on the bore of the balancer shaft bearing hole refer to the section on Crankcase Plain Bearing A Crankshaft B Balancer Gear C Matching Mark Reassembly e Install the balancer shaft in the crankcase by aligning the matching mark on the balancer gear with the matching mark on the balancer drive gear of the crankshaft PS FE314051 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 61 Camshaft Disassembly e Remove the crankcase cover e If axial play adjustment shims are provided for the crankshaft and the camshaft remove the shims and identify them so that they can be installed correctly during reassembly e Place the cylinder block on a base so that the flywheel side faces down Keep the tappet or the HLA on FE350 or 400 pushed up towards the cylinder head e After aligning the matching marks on the crankshaft gear and the camshaft gear take out the camshaft NOTE FE3141S1 Clean the mating surfaces of the crankcase and the crankcase cover of any gasket residues e Take out the tappet or the HLA f
4. ACG Inspection e Disconnect the connectors from the alternator connect a hand tester to the lead of the charging coil and the ground in order to measure the internal resistance of the charging coil ACG Internal Resistance Coil Type Specified Range 2 12V 2A 0 40 0 67 12V 4A 0 82 1 38 12V 13A 0 26 0 44 AE XIP the measured value is out of the specified range replace the charging coil x If the resistance of the coil is normal but there is no voltage the rotor s magnetic force has diminished so the rotor must be replaced A ACG Lead green white B Ground Rectifier Inspection e Set the resistance measurement range of the hand tester to R x 1 kQ e Measure the resistance between the male and female connectors in both positive and negative directions x If the measured values are lower in one direction and the other direction is oo the rectifier is normal The lower value should generally be between 0 and the halfway point of the scale although this could vary from tester to tester x If the measured value differs from the above the rectifier is defective so it must be replaced with a good one FE303081 1 Rectifier 2 Male Connector 3 Female Connector 3 20 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Charging System Regulator Inspection e Disconnect the connector from the regulator e Set the measurement range of the hand tester to R x 1 kQ and measure the re
5. Disassembly Area Precaution Name Quantity Drain Plug Warm up engine and drain oil 14 across Fuel Tap Fuel Tank Drain fuel before disassembly M6 bolt tap 1 M6 bolt tank 6 Spark Plug 21 across Muffler Assembly Remove the exhaust pipe cover M6 bolt 2 M6 nut with washer 1 Remove the muffler assembly M8 nut 2 M8 bolt 1 Wiring Related Disconnect ground wire M8 nut 1 Disconnect connecting terminals Panel Control Remove it from tank bracket M5 screw 4 Tank Bracket M8 bolt 4 Control Related e Link Rod and Spring e Governor Arm M6 nut 1 e Control Panel Assembly M6 bolt 2 Starter Motor M8 bolt 2 Air Cleaner M6 batterfly bolt 2 Carburetor Also remove insulator M6 nut 2 M6 bolt 1 Three piece Shroud and Fan M6 bolt 15 Housing M6 tower bolt 1 Electrical Remove clamp and lead M5 tapping screw 2 e Ignition Coil M5 bolt 2 e Flywheel FE350 400 use M18 nut M16 nut 1 e ACG M6 screw 2or4 Cylinder Head e Rocker Case M6 bolt 2 e Cylinder Head Loosen bolts evenlly in reverse of tightening M8 bolt 6 Valve System e Pushrods Identify intake and exhaust Identification unnecessary for FE350 400 e Rocker Arm Identify intake and exhaust for FE250 M6 nut 2 for FE290 350 400 E ring 1 e Exhaust Valve Crankcase Cover Shaft Adjust Shims Identify shims for crankshaft and camshaft M8 bolt 8 Camshaft Remove shaft from a position where cam gear marks are aligned Tappets FE250 290 Identify intake and exhaust or HLA Devices FE3
6. e Before reassembly wipe the flywheel and the tapered portion of the crankshaft to remove any dust or oil e Make sure that the woodruff key is installed correctly in the groove of the crankshaft install the flywheel and install the retaining nut e Using a strap wrench hold the flywheel and tighten the flywheel nut to the specified torque Refer to the Tightening Torque Specifications table A Flywheel Nut 3 18 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Ignition System Ignition Coil Reassembly Air Gap Adjustment e Rotate the flywheel so that the magnet on the flywheel is on the opposite side of the area in which the ignition coil is to be installed e Use two bolts to hand tighten the ignition coil to the area in which the coil is to be installed and slide a 0 3 mm gap gauge between the foot of the coil and the periphery of the flywheel e Keep the ignition coil pressed towards the flywheel and evenly tighten the coil retaining bolts to the specified torque Ignition Coil Air Gap Standard 0 3 mm 0 012 in Adjustable Range 0 25 0 4 mm 0 010 0 016 in a Ignition Coil Retaining Bolt Specified Tightening Torque FE120 M6 bolt 6 0 N m 0 6 kg m 53 in Ib FE170 250 290 350 400 3 5 N m 0 35 kom 31 in Ib A Magnet B Coil Foot C Coil Retaining Botls D Gap Gauge Key Switch engine switch Inspection e Set the measurement range of the hand tester to Rx19 and check Kee
7. 11 mmm QION mmm AN QON TTN Kawasaki 4 stroke air cooled gasoline engine Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Department Consumer Products amp Machinery Group Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts Kawasaki Heavy Industries Ltd 2000 First Edition 1 Sep 1 2000 K LIST OF ABBREVIATIONS A ampere s ABDC after bottom dead center AC alternating current ATDC after top dead center BBDC before bottom dead center BDC bottom dead center BTDC before top dead center C degree s Celsius DC direct current F farad s F degree s Fahrenheit ft foot feet g gram s h hour s
8. No Remove a spark plug touch it against the engine block and crank the engine to check for sparks Because gasoline in the form of atomized air fuel mixture is discharged through the spark plug hole in the engine at this time place the spark plug as far away as possible gt Are sparks produced from the spark plug hole while making contact WARNING To prevent electrical shock do not hold the spark plug itself Make sure to hold the plug cap Yes Yes gt Is compression sufficient when the spark plug is replaced Are sparks produced between the tip of the high tension lead with the spark plug cap removed and the engine block while the engine is Yes being cranked Are sparks produced between the high tension lead and the engine block when the ignition coil is replaced Choke the carburetor crank the engine a few times remove the spark plug and check its electrode Is it wet No Check the carburetor Yes Check for plugged fuel line Check for plugged air passage e Check fuel level in float bowl e Check carburetor setting Yes Spark plug faulty Contact faulty between plug cap and high tension lead Replace Correct e Igniter faulty Replace e Faulty switch e Air gap between ignition coil and magnet incorrect Flywheel demagnetized No fuel in the tank e Fuel pipe or
9. Crankshaft Journal Diameter Service Limit minimum unit mm FE120 FE170 FE250 FE290 FE350 400 19 930 29 930 29 930 34 930 eh TE 0 7846 in 1 1783 in 1 1783 in 1 3752 in ae EE 19 930 29 930 29 930 34 930 T 0 7846 in 1 1783 in 1 1783 in 1 3752 in 46 924 46 924 49 924 Balancer Hink Rod Joumal 1 8474 in 1 8474 in 1 9655 in AA 25 944 28 944 33 944 35 444 37 444 p 1 0214 in 1 1395 in 1 3394 in 1 3954 in 1 4742 in e Using center support tools B as shown in the diagram support both ends of the crankshaft Place a dial gauge A on the journal and slowly turn the crankshaft to measure the fluctuation the variance between the maximum and minimum values of the dial gauge which is the runout of the crankshaft Crankshaft Runout Service Limit maximum Service Limit 0 5 mm 0 02 in TIR Xx If the measured value is greater than the service limit replace the crankshaft with a new one Crankshaft Axial Play Adjustment If a part that affects the axial play has been replaced the axial play must be adjusted as described below Shim adjustment is not available on the FE120 and 170 Note Except the FE170 for pump application e Place a gasket on the crankcase and measure and record the distance from the gasket surface to the crankshaft gear surface measurement A e Measure and record the distance from the crankcase cover mating surface to the end face of the crankshaft bearing inner ra
10. O Be careful not to deform the starter motor when securing the starter motor on a vise e Connect the positive lead of the battery to terminal D of the solenoid e Momentarily place the negative lead of the battery in contact with a non painted area of the starter motor body x If the pinion gear does not spin repair or replace the starter motor Brush Overall Length Measurement Measure the overall length of the brushes If the brushes are shorter than their service limit replace them with new ones Brush Overall Length Service Limit minimum Sift Lever Type P N 21163 2089 2095 6 0 mm 0 24 in Bendix Type P N 21163 2108 3 5 mm 0 14 in Bendix Type P N 21163 2096 8 5 mm 0 33 in 3 24 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Starter System Commutator Diameter Measurement Measure the diameter of the commutator at several areas If the diameter is smaller than the service limit replace the armature Commutator Diameter Service Limit minimum Sift Lever Type P N 21163 2089 2095 27 mm 1 06 in Bendix Type P N 21163 2108 23 mm 0 91 in Bendix Type P N 21163 2096 27 mm 1 06 in FESO41S1 Commutator Groove Depth Measure the depth of the grooves between the segments of the x commutator O x If the groove depth is smaller than the service limit use a thin file or a piece of steel to file the insulation portion to the standard depth C
11. e Verify that the oil level in the engine is normal e Disconnect the wire from the oil level sensor terminal e Start the engine and operate it at a low speed e Connect one of the test leads to the wire that was disconnected in step 2 above and the other end to the engine ground to stop the engine xk If the engine does not stop inspect the wires and connections x If the wires and connections are normal the igniter with oil level warning light is faulty and must be replaced e Connect the test leads in the same way as in step 4 above and start FES11881 the engine again x If the oil level warning light illuminates and the engine does not start the system is normal If the oil level warning light does not illuminate the oil level warning light LED is faulty and the igniter must be replaced A Test Lead B Connection C Oil Level Sensor Terminal Controller with oil level warning light inspection integrated type e Verify that the oil level in the engine is normal e Disconnect the wire from the oil level sensor terminal e Start the engine and operate it at a low speed e Connect one of the test leads to the wire that was disconnected in step 2 above and the other end to the engine ground to stop the engine xk If the engine does not stop inspect the wires and connections x If the wires and connections are normal the controller with oil level warning light is faulty and must be replaced e Connect the
12. 350 and 400 also handle the recoil spring carefully to prevent it from jumping out and do not reverse the winding direction of the recoil spring and the rope T1 Tightening Torque 10 N m 1 0 kg m 7 2 ft lb T2 Tightening Torque 6 N m 0 6 kg m 4 3 ft lb ee G Apply grease L Apply non coagulating thread lock Reassembly e Do not reverse the direction of the coil spring during reassembly Ap ply grease to the recoil spring and the case shaft before reassembly e Attach the reel to the case so that the inner hook of the recoil spring engages securely with the case hook e Assemble the tab tab spring and guide plate in their original positions Apply a non coagulating type thread lock on the threaded portion of the retaining screw and tighten the screw e To apply an initial load to the recoil spring rotate the reel two turns in a direction that compresses the recoil spring Hold the reel pass the end of the rope through the hole in the case and make a tentative knot e Insert the end of the rope into the handle make the final knot there and undo the tentative knot e Pull on the rope and make sure that the tab operates normally A Recoil Spring Inner Hook B Case Hook C Case Shaft FESOA6S1 3 26 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Cylinder Head Compression Inspection e After warming up the engine stop the engine Remove the spark plug and connect a compression gauge to
13. FE170 29 052 mm 1 1438 in FE250 34 067 mm 1 3412 in FE290 35 567 mm 1 4003 in FE350 400 37 567 mm 1 4790 in x If the measured value is greater than the service limit replace the connecting rod with a new one e Insert a bar each measuring approximately 100 mm in length and almost the same diameter as the respective bore into both the big and small ends of the connecting rod Then set the V block and the dial gauge as shown in the diagram in order to measure the bend and twist of the connecting rod x If the measured value is greater than the service limit replace the connecting rod with a new one Connecting Rod Bend and Twist Service Limit maximum Service Limit 0 15 100 mm 0 006 100 in A Big End Bearing Area B Small End Bearing Area FE309351 3 42 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Piston and Connecting Rod A Dial Gauge B V Block DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 43 Cylinder Block and Crankcase Cover Cylinder Inspection e Inspect the cylinder wall for the presence of any scratches the cylinder exterior for any broken fins and for any other damage x If the cylinder has non repairable damage replace the cylinder block with a new one e Using a cylinder gauge measure the cylinder bore in the longitudinal and latitudinal directions at the locations given in the diagram on the right Cylinder Bore Service Limit maximum FE12
14. The numbers indicate the nominal numbers of the ball bearings e To inspect a ball bearing first clean the bearing in solvent and allow it to dry Then apply engine oil and gently spin it with your hand x If the bearing is noisy does not spin smoothly or has excessive play replace the bearing DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 45 Cylinder Block and Crankcase Cover Replace a ball bearing in the following manner e Remove the oil seal Do not reuse an oil seal once it has been removed e Using a bearing puller as shown in the diagram on the right remove the bearing e Clean the bearing housing and allow it to dry e Apply oil to a new bearing e Using a bearing driver drive the bearing in until it is flush with the end face of the housing FE310151 Oil Seal e Once an oil seal is removed replace it with a new one e To install an oil seal use a press or a seal driver e Only on the PTO side of the type D engine the oil seal must be driven in 4 mm lower than the crankcase cover surface as shown in the diagram Other oil seals must be installed flush with the case surface 1 Oil Seal 2 Crankcase Cover FE310251 e Fill the area between oil seal lips A and B with high temperature grease before installing the oil seal NOTE O Use a guide jig to install the oil seal without damaging its lip A Lip A B Lip B C Crankcase or Crankcase Cover Plain Bearing Area Inspe
15. and read the resistance between terminal C and a ground on the unit The solenoid is normal if the resistance is approximately 0 If it is not replace the solenoid FE303482 FE303681 P FE303751 P DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 23 Starter System e Connect lead B to terminal C Set the measurement range of the tester to R x 1 Q and connect it to the two terminals on the solenoid Turn the key switch to the START position to read the tester x If the solenoid clicks once the tester reads 0 N and the pinion gear advances forward the solenoid and the wiring are normal x If the solenoid does not make a clicking sound and the reading on the tester is greater than 0 2 the solenoid is defective and it must be replaced x If the solenoid clicks once and the reading on the tester is greater than 0 2 the solenoid is defective and it must be replaced FE3038S1 P Starter Motor Inspection CAUTION Make sure that there are no flammable substances in the work area Always keep the pinion gear of the starter motor away from your body e Disconnect the leads at the battery before removing the starter motor NOTE O First disconnect the negative lead of the battery followed by the positive lead to prevent sparks from being created during the operation e Remove the starter motor from the engine e Secure the starter motor on a vise NOTE
16. liter s Ib m min N Pa PS psi rpm pound s meter s minute s newton s pascal s horsepower pound s per square inch revolution revolution s per minute top dead center total indicator reading volt s watt s ohm s Read OWNER S MANUAL before operating EMISSION CONTROL INFORMATION To protect the environment in which we live Kawasaki has incorporated crankcase emission 1 and exhaust emission 2 control systems in compliance with applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board 1 Crankcase Emission Control System A sealed type crankcase emission control system is used to eliminate blow by gasses The blow by gasses are led to a breather chamber through the crankcase and from there to the air cleaner Oil is separated from the gasses while passing through the inside of the breather chamber from the crankcase and then returned to the bottom of the crankcase 2 Exhaust Emission Control System The exhaust emission control system applied to this engine consists of a carburetor and an ignition system having optimum ignition timing characteristics The carburetor has been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED Federal law and California State law prohibits the following acts or the
17. the correct shim thickness is t 1 60 Selection Table mm e S Ss JE 2 2 de gt ae s Measurement B Cam Shaft Axial Play Standard and Service Limit maximum for Type G Unit mm Srandard Service Limit FE120 170 0 08 0 34 0 0031 0 0134 in 0 50 0 0197 in FE250 0 05 0 17 0 0020 0 0067 in 0 35 0 0138 in FE290 350 400 0 07 0 21 0 0028 0 0083 in 0 35 0 0138 in
18. 17 975 mm 0 7077 in FE290 18 975 mm 0 7470 in FE350 400 19 975 mm 0 7864 in x If the measured value is smaller than the service limit replace the FE308951 piston pin with a new one A Piston Pin Piston Ring Inspection e Using a micrometer measure the thickness of the piston ring in several places Piston Ring Thickness Service Limit minimum for both Top and Second Rings FE120 170 1 42 mm 0 056 in FE250 290 350 400 1 44 mm 0 057 in Xx If the measured value is smaller than the service limit replace the piston rings as a set FE309051 e Fit the piston ring inside the cylinder and use the top of the piston to insert the piston ring perpendicularly to the skirt area at the bottom of the cylinder Then use a gap gauge to measure the clearance of the ring gap Piston Ring Gap Clearance Service Limit maximum Top Ring Second Ring FE120 170 1 0 mm 0 039 in 1 0 mm 0 039 in FE290 350 400 1 2 mm 0 047 in 1 2 mm 0 047 in Xx If the measured value is greater than the service limit replace the piston rings as a set This is because of the difficulty in properly FE309151 measuring the oil ring A Piston Ring B Ring Gap Clearance DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 41 Piston and Connecting Rod Connecting Rod Inspection e Inspect the big end of the connecting rod for wear or any traces of seizure scratches or discoloration X Abnormal
19. G Dimensions LxWxH mm 344 5 x 395 x 432 363 x 408 x 441 378 x 422 x 454 378 x 422 x 459 in 13 56 x 15 55 x 17 01 14 29 x 16 06 x 17 36 14 88 x 16 61 x 17 87 14 88 x 16 61 x 18 07 Dry Weight kg With recoil starter With erectic starter kg Engine Type of engine Air cooled 4 stroke OHV Single cylinder Gasoline engine Bore x Stroke 76 x 55 78 x 60 83 x 65 87 x 67 5 i 2 99 x 2 17 3 07 x 2 36 3 27 x 2 56 3 43 x 2 66 Displacement 249 286 351 401 15 2 17 5 21 4 24 5 Direction of rotation Counterclockwise facing PTO Shaft Fast Idle Speed 4000 Slow Idle Speed 1300 Fuel information Unleaded Gasoline Fuel tank capacity 6 0 6 4 6 4 Lubrication system Pressurized lubrication with oil filter Engine Oil SAE 10W30 SF SG SH or SJ Oil Pan Capacity a e ES T 1 e AE i 0 8 L 1 0 L Carburetor Float Butterfly Type Spark Plug NGK BPR 5ES Starting system Recoil starter with ACR or electric starter Governor Mechanical flyweight Type of Reduction 1 2 gear 1 2 gear 1 2 gear 1 2 gear reduction reduction reduction reduction Air Cleaner Dual Element Specifications are subject to change without notice and may not apply to every country 1 6 GENERAL INFORMATION Periodic Maintenance Chart To ensure satisfactory operation over an extended period of time any engine requires normal maintenance regular intervals The Periodic Maintenance Ch
20. Limits indicate the usable limits If the measurement shows excessive wear or deteriorated performance replace the damaged parts 1 4 GENERAL INFORMATION General Specifications Item FE120 FE170 Type D Type G Type D Type G Dimensions LxWxH mm 291 x 349 x 344 300 x 354 x 370 in 11 46 x 13 43 x 19 54 11 81 x 13 94 x 14 57 Dry Weight kg 14 5 16 8 Engine Type of engine Air cooled 4 stroke OHV Single cylinder Gasoline engine Number of Cylinder 1 Bore x Stroke mm 60 x 44 66 x 50 in 2 36 x 1 73 2 60 x 1 97 Displacement mL 124 171 cu in 7 6 10 4 Direction of rotarion Counterclockwise facing PTO Shaft Fast Idle Speed rpm 4000 Slow Idle Speed rpm 1600 Fuel information Unleaded Gasoline Fuel tank capacity L 2 5 3 4 Lubrication system Splash Engine Oil SAE 10W30 SF SG SH or SJ Oil Pan Capacity Max 0 6L 0 6L Min 0 35 L 0 35 L Carburetor Float Butterfly Type Ignition system Transistor Flywheel Magneto Spark Plug Starting system NGK BPR 5ES Recoil starter with ACR or electric starter Governor Mechanical flyweight Type of Reduction 1 2 gear reduction 1 2 gear reduction Air Cleaner Dual Element Specifications are subject to change without notice and may not apply to every country GENERAL INFORMATION 1 5 General Specifications Item FE250 FE290 FE350 FE400 Type D Type G Type D Type G Type D TypeG TypeD Type
21. R ES IR oo i et M D FT Hee T T RW So i Ee E Ca SERIES EN BE Py SRT m RITA m la 7 CITT SI L TTT m TTT m TTT wi Ba I AIN BR a m TTT E TTT Ca ITT Bi AAA I 9 05 00 8 95 Measurement B Measurement A Unit mm FE250G Camshaft Shim Selection Table E JUNE N EEE P HG E R S v HE HE NC BE E ZT L L LI c PUE E SE E R E cb q CH AA AA o A O A q gi w i Measurement B Measurement A FE290G Camshaft Shim Selection Table Unit mm ATT ALTA UYU AT HAA TATA MATA DAT un L mas et CS S E 1 I CG S LIMIT UTA AIN A AAT MAA Measurement B Measurement A FE315192 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 65 Camshaft Apply these measurements on the crankshaft shim selection table and select the next thinner shim X For example on the FE350D if measurement A is 13 41 mm and measurement B is 14 09 mm the correct shim thickness is t 0 4 FE350D FE400D Camshaft Shim Selection Table Unit mm mm lt 5 E gt S Measurement B For example on the FE350G if measurement A is 15 85 mm and FE350G FE400G Cam Shaft Shim measurement B is 17 70 mm
22. TypeG TypeD TypeG TypeD TypeG Compression minimum with Recoil Starter 290 kPa 3 kg cm 42 psi with Electric Starter 390 kPa 4 kg cm 57 psi Cylinder Bore maximum 60 067 66 067 76 070 2 3648 in 2 3648 in 2 9949 in Roundness maximum 0 056 0 0022 in Boring Size oversize 0 50 0 0120 in Crankcase Area Crankshaft Bearing Bore maximum Camshaft Bearing Bore maximum 15 063 16 063 20 063 0 593 in 0 6324 in 0 7899 in Balancer Shaft Bearing Bore maximum 15 063 0 5930 in Oil Pump Housing Bore maximum Oil Pump Housing Depth maximum Oil Pump Shaft Bearing Bore maximum Crankcase Cover ac ar Camshaft Bearing Bore maximum 15 063 16 063 20 063 0 5930 in 0 6324 in 0 7899 in Crankshaft Crankpin Diameter minimum 25 944 28 944 33 944 1 0214 in 1 1395 in 1 3363 in Crankshaft Journal Diameter PTO Side minimum 19 930 24 930 29 930 0 7846 in 0 9815 in 1 1783 in Flywheel Side minimum 19 930 24 930 29 930 0 7846 in 0 9815 in 1 1783 in Balancer Link Rod Journal minimum Shaft Runout TIR maximum 0 05 0 0020 in Axial Play maximum 0 5 0 35 0 0197 in 0 0138 in standard 0 0 24 standard 0 03 0 30 standard 0 05 0 17 0 0 0094 in 0 0012 0 0119 in 0 0020 0 0067 in Camshaft Camshaft Journal Diameter PTO Side minimum 14 910 19 930 15 910 24 930 19 927 29 930 0 5
23. Valve C Governor Shaft D Clamp Nut E Pin FE301382 P 3 10 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Air Cleaner The quality of the inspection or maintenance of the air cleaner significantly affects the durability and the performance of the engine If the engine is used in a dusty area the air cleaner element should be cleaned more frequently than the regular inspection intervals Element Cleaning e The sponge element should be used slightly wet with oil To clean the sponge element first wash it thoroughly in cold or warm water that contains detergent Then rinse it in plain water and allow it to dry Immerse the element in fresh engine oil wrap it in a clean cloth squeeze the oil out of it and install the element while it retains some oil e To clean the paper element gently tap on the steel end plate of the element to remove the dust Otherwise wash it in a soap solution by shaking it rinse it in water and allow it to air dry If the element is extremely dirty replace it with a new one Type A for FE120 170 Type B for FE250 290 350 400 1 Sponge Element 2 Paper Element FENES DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 11 Cooling System All the cooling fans of the FE series engines are the separate type that can be separated from the flywheel FE290 type NOTE O On the engine produced before May 1996 the flywheel and the cooling fan are integrate
24. available in North America is Standard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent 8 Gasket O Ring Do not reuse a gasket or O ring once it has been in service The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks 9 Liquid Gasket Non Permanent Locking Agent Follow manufacturer s directions for cleaning and preparing surfaces where these compounds will be used Apply sparingly Excessive amounts may block engine oil passages and cause serious damage An example of a non permanent locking agent commonly available in North America is Loctite Lock n Seal Blue 10 Press A part installed using a press or driver such as a journal should first be coated with oil on its outer or inner circumference so that it will go into place smoothly 11 Ball Bearing When installing a ball bearing the bearing race which is affected by friction should be pushed by a suitable driver This prevents severe stress on the balls and races and prevents races and balls from being dented Press a ball bearing until it stops at the stop in the hole or on the shaft 12 Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally damages seals When pressing in a seal which has manufacturer s marks press it in with the marks facing out Seals should be pressed into pla
25. causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new engine for the purpose of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the engine after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Do not tamper with the original emission related part Carburetor and internal parts Spark plugs Magneto or electronic ignition system Fuel filter element Air cleaner elements Crankcase Cylinder heads Breather chamber and internal parts Intake pipe and tube Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily Whenever the owner has insufficient experience or doubts as to his ability to do the work all adjustments maintenance and repair should be carried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read
26. example go to the Periodic Maintenance Chart first The chart tells you how frequently to clean and gap the plug Next use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chapter to find the Spark Plug section Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices This warning symbol identifies special instruc tions or procedures which if not correctly fol lowed could result in personal injury or loss of life CAUTION This caution symbol identifies special instruc tions or procedures which if not strictly ob served could result in damage to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of information NOTE O This note symbol indicates points of particular in terest for more efficient and convenient operation e Indicates a procedural step or work to be done O Indicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a WARNING CAUTION or NOTE Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub step it follows In most chapters an exploded view illustration of the system components follows the Table of Con
27. governor lever moves in the direction to open the throttle valve Ordinarily fluctuations in the load that is applied to the engine also cause the engine speed to fluctuate When the load decreases suddenly the engine speed increases momentarily but because the governor weight moves the throttle valve in the closing direction the engine speed is kept constant When the load increases suddenly the engine speed decreases momentarily but because the governor arm is retracted by the governor spring the throttle moves in the opening direction to keep the engine speed constant Throttle Lever Carburetor Governor Weight Sleeve Camshaft FE300982 Crankshaft Governor Shaft Governor Arm Throttle Valve Link Rod Governor Spring ACIOT7mMmU00O0U gt FE301051 3 8 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Governor Mechanism Governor Gear Assembly Installation CAUTION Do not remove the governor gear assembly unless the parts are to be replaced The parts cannot be reused once they are removed e Use two screwdrivers of an appropriate size to remove the governor gear assembly Protect the surface of the gasket on the crankcase cover to prevent it from becoming damaged during the removal of the governor gear assembly e Install the sleeve on the governor gear assembly before the installa tion of the governor gear assembly NOTE O The sleeve cannot be installed af
28. maximum 0 15 0 0059 in Second Ring maximum 0 12 E 0 0047 in Piston Pin Hole Bore maximum 14 033 16 033 18 033 0 5525 in 0 6312 in 0 7100 in Piston Pin Diameter minimum 13 975 15 975 17 975 0 5502 in 0 6289 in 0 7077 in 2 4 SERVICE DATA Service Specifications Service Limit mm Item FE290 FE350 FE400 Type D Type G TypeD TypeG Type D Type G Compression minimum with Recoil Starter 290 kPa 3 kg cm 42 psi with Electric Starter 390 kPa 4 kg cm 57 psi Cylinder Bore maximum 78 067 83 067 87 067 3 0735 in 3 2703 in 3 4278 in Roundness maximum 0 056 0 0022 in Boring Size oversize 0 50 0 0197 in Crankcase Area Crankshaft Bearing Bore maximum 30 075 35 075 1 1841 in 1 3809 in Camshaft Bearing Bore maximum 23 063 0 9080 in Balancer Shaft Bearing Bore maximum Oil Pump Housing Bore maximum 40 766 1 6050 in Oil Pump Housing Depth maximum 10 170 0 4004 in Oil Pump Shaft Bearing Bore maximum 12 770 0 5028 in Crankcase Cover Camshaft Bearing Bore maximum 23 063 23 063 23 063 0 9080 in 0 9080 in 0 9080 in Crankshaft Crankpin Diameter minimum 35 444 37 444 1 3954 in 1 4742 in Crankshaft Journal Diameter PTO Side minimum 29 930 34 930 1 1783 in 1 3752 in Flywheel Side minimum 29 930 34 930 1 1783 in 1 3752 in Balancer Link Rod Journal minimum 46 92
29. mm 0 2132 in FE250 5 930 mm 0 2335 in 5 915 mm 0 2329 in FE290 350 400 6 930 mm 0 2728 in 6 915 mm 0 2722 in e Support both ends of the valve stem on V blocks A as shown in the diagram Place a dial gauge B against the center and gently rotate the valve stem to measure the bend of the stem by reading the entire fluctuation of the dial gauge Valve Stem Bend Service Limit maximum for both Intake and Exhaust FE120 170 0 05 mm 0 0020 in FE250 290 350 400 0 03 mm 0 0012 in Xx If the measured value is greater than the service limit replace the valve with a new one Valve Spring Inspection e Inspect the valve spring for the presence of corrosion or cracks and replace it with a new one if necessary e Using a vernier caliper measure the free length of the valve spring Valve Spring Free Lenght Service Limit minium for both Intake and Exhaust FE120 170 31 8 mm 1 25 in FE250 290 32 8 mm 1 29 in FE350 400 38 1 mm 1 50 in x If the free length is shorter than the service limit replace the valve spring with a new one NOTE O During reassembly beware that the spring pitch is smaller at the valve seat side of the valve spring on the FE250 290 350 and 400 For both intake and exhaust valves A Valve Spring FE306851 FES306981 FE307081 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 35 Valve System Valve Seat Inspection and La
30. not use large tools to apply excessive force in order to tighten the screws Make sure to use a tool that is appropriate for the respective part and carefully tighten the screws e The screws used for retaining the throttle valve and the choke valve are crimped at their threaded ends to prevent them from loosening Therefore do not disassemble them unnecessarily A Spring B Float Valve C Ear Shaped Protrusion D Spring Groove Adjustment Ordinarily it is not necessary to adjust the carburetor because it is adjusted at the factory to an optimal fuel setting However if the engine runs poorly follow the procedures given below to adjust the carburetor Pilot Screw Adjustment e Slowly turn the pilot screw in the clockwise direction until a slight resistance is felt e Then back out the pilot screw two turns counterclockwise for tentative setting e Install the air cleaner in the normal manner and warm up the engine by operating it without a load e Set the speed adjustment lever to the low speed idling position e Keep the throttle lever on the carburetor pushed gently to the fully closed position and turn the idle adjustment screw so that the engine attains the idle speed e Keep the throttle lever pushed to the fully closed position and turn the pilot screw in and out to find the position in which the idle speed of the engine is at the highest rpm From that position back out the pilot screw one quarter of a turn in
31. passage to make sure that they are not plugged e Remove retaining screw 8 on the inside of the tank cap and remove spring plate 7 NOTE O Retaining screw 8 is a tapping screw so make sure not to crush the threads It is best not to overtighten the screw Fuel Tank Fuel Filter fuel tap Filter Pot Tank Cap Fuel Gauge Filter strainer Spring Plate Retaining Screw GO JO Qn E GM e Use adhesive tape to cover hole A from which the screw was removed Place your mouth on air hole B to blow air into it and verify that air comes out with great force from air passage C If air does not come out of the air passage or if it is weak replace the tank cap with a new one A Thread Hole B Air Hole C Air Passage FE301482 FE301582 P DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 13 Ignition System Description of Function The ignition mechanism is the transistorized type and consists of the following parts Ignition Coil Igniter Flywheel with permanent magnet These components do not contain mechanical contact parts and do not require regular inspection Electronic Ignition Device e The revolution of the flywheel generates voltage between terminals A and B causing base current IB1 to flow from TR1 Then current IC1 that is amplified by TR1 flows to form the primary circuit e The flywheel revolves further and the voltage that is generated between t
32. screwdriver to pry up on the link rod thus removing the link rod from the hole in the throttle lever To reinstall the link rod use your fingers to press the link rod into the hole Use a pair of pliers or a flat blade screwdriver to remove and reinstall the linkage spring e During disassembly carefully note the orientation top bottom right left etc of the gaskets so that they can be replaced correctly during reassembly All gaskets must be replaced with new ones e Use a solvent with a high flash point to wash the carburetor and make sure to prevent contamination by foreign matter CAUTION Gasoline is extremely dangerous due to its high volatility Han dle it away from sparks or fire and ensure proper ventilation NOTE O Do not use a solvent with rubber or plastic parts e Spray carburetor cleaner into the internal holes in the carburetor to ensure their opening Then wash the carburetor in hot water allow it to dry naturally and blow clean compressed air through the holes if necessary 3 4 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Carburetor e Check how the float valve spring is fitted Make sure that the first coil of the float valve spring is completely wrapped in both spring grooves that are provided at the two ear shaped protrusions on the float valve body NOTE O Do not unnecessarily disassemble the float valve spring because this could damage the valve spring CAUTION Do
33. test leads in the same way as in step 4 above and start the engine again x If the oil level warning light illuminates and the engine does not start the system is normal x If the oil level warning light does not illuminate the oil level warning light LED is faulty and the controller must be replaced 3 52 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Lubrication System Breather The function of the breather is to maintain a vacuum in the crankcase to prevent the engine oil from being discharged outside the engine The breather valve regulates the flow of the air that is created by the movement of the piston by allowing the air to flow from the inside of the crankcase to the outside while preventing the air from the outside of the crankcase to enter inside In the rocker case the maze and the volumetric expansion of the rocker case causes the air containing oil to separate into oil and air The air from the crankcase ultimately flows to the air cleaner and mixes with the intake air Inspection Method e With the rocker case installed in place blow air or apply suction to the breather pipe in order to activate the breather valve Verify that the breather valve closes when air is blown into the pipe e Remove the retaining screws from the breather valve and inspect the valve and valve seat for the presence of damage cracks or wear e Using a gap gauge measure the clearance between the breather valve and valve seat A
34. the piston opposite to the side of the connecting rod marked MADE IN JAPAN e On type G face the arrow on the top of the piston towards the side of the connecting rod marked MADE IN JAPAN e Replace the snap ring for the piston pin with a new one and fit it securely into the groove of the piston pin hole NOTE O Do not reuse an old snap ring Once a snap ring is removed it could be deformed or it could have lost its tension If it is reused it could fall out while the engine is running and damage the cylinder wall e When installing the piston and connecting rod assembly into the cylinder beware of the direction of the MADE IN JAPAN side of the connecting rod NOTE O Apply engine oil to the cylinder bore crank pin area connecting rod big end and connecting rod bolts before reassembly A Piston B Connecting Rod C Arrow Type D Type G FE308582 For FE120 170 250 350 400 e On both types D and G the MADE IN JAPAN side of the connecting rod must face the magneto For FE290 On both types D and G the MADE IN JAPAN side of the connecting rod must face the output shaft e Arrange the gaps of the piston rings as shown in the diagram and use a ring compressor to install the piston from the cylinder head side e Mate the connecting rod cap to the big end of the connecting rod and tighten the connecting rod bolts to the specified torque Refer to the section on Tightening Torque Specifications NOT
35. the solenoid switch thus causing the solenoid to actuate and the solenoid switch to close This causes a large current to flow to the starter motor enabling the starter motor to start rotating When the starter motor starts rotating the pinion moves by inertia to the ring gear outer side along the free sliding threads that are cut on the armature s outer periphery and on the inside of the pinion gear As the pinion gear meshes with the ring gear in this manner the rotational movement of the starter motor is transmitted to the crankshaft When the engine starts and the key switch is turned to the ON run position the current to the solenoid is cut off causing the plunger and the solenoid switch to return to their original positions On the shift lever type the pinion gear separates from the ring gear and returns to its original position simultaneously with the return of the plunger On the Bendix type the inertia of the ring gear causes the pinion gear to return to the starter inner side along the free sliding threads thus returning to its original position SES CAUTION Do not operate the starter motor continuously for more than 5 seconds Turn OFF the switch after 5 seconds then allow approximately 15 seconds to elapse before operating the starter again Operating the starter for a long time could drain the battery and burn the starter motor Nut Nut Solenoid Bolt Rear Cover Insulator Brus
36. the spark plug hole NOTE O Connect the spark plug cap to the removed spark plug and ground the spark plug against the engine body Make sure that there are no flammable substances in the surrounding area O If the engine is equipped with an electric starter make sure that the battery is fully charged e Fully open the engine throttle and the choke valve Operate the recoil starter or electric starter and read the maximum compression Compression minimum with Recoil Starter 290 kPa 3 kg cm 42 psi with Electric Starter 390 kPa 4 kg cm 57 psi x If the compression reading is lower than the minimum value given above refer to the Troubleshooting section in order to repair the engine A Installing the compression gauge Disassembly e Remove the retaining bolts from the rocker cover and remove the rocker cover together with the breather pipe e Remove the rocker arm X Bring the piston to the top dead center of the compression stroke This will allow the rocker arm to move freely except FE350 and 400 On the FE120 170 and 250 loosen the lock nut on the rocker arm pivot to remove the lock nut and the rocker arm pivot Then remove the rocker arm X On the FE290 350 and 400 remove the E ring push the rocker shaft towards the exhaust side and remove the washer and the rocker arm e Remove the pushrods NOTE O Mark the pushrods to prevent the intake and exhaust positions from becoming interchanged during rea
37. the specified torque Refer to the section on Tightening Torque Specifications A Adjustment Bolt B Locknut C Gap Gauge Automatic Compression Release ACR Device Inspection The ACR reduces the compression of the cylinder in order to facilitate the revolution of the crankshaft during the starting of the engine e Detach the rocker cover and remove the spark plug e Check whether the valves have the specified clearance e Slowly turn the crankshaft in the direction of the engine rotation and observe the movement of the exhaust valve A and the rocker arm B X Immediately after the intake valve has closed the rocker arm B should push open the exhaust valve A to attain a lift that is greater than the service limit given below If the exhaust valve does not lift to that height the ACR that is provided on the camshaft is faulty Refer to the section on Camshaft Inspection Valve Lift Height Service Limit minimum by ACR for Exhaust FE120 170 250 290 0 6 mm 0 024 in FE350 400 1 0 mm 0 039 in Valve Disassembly and Reassembly For FE120 170 Disassembly e Place an appropriate receiving plate on the combustion chamber side of the cylinder head e Using your thumbs push down the spring retainer slide the retainer towards the side hole and remove the retainer e Remove the spring and the valve Reassembly e Verify that the valve seat is making proper contact and that the valve stem moves smoothly in the guide
38. whether the lead from the key switch exhibits the continuity indicated Key Switch in the table on the right Postion ana ann ram m If the leads exhibit the continuity indicated in the table on the right OFF Cie the key switch is good en Too START OO Os Continuity FE302751 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 19 Charging System The state of charge of the battery must be determined by measuring the terminal voltage of the individual battery Individual Battery s Terminal Voltage Standard 12V x If the terminal voltage is below the standard the battery must be recharged Charging System Inspection Fully recharge the battery before inspecting the charging system e Warm up the engine Rectifier or e Connect a voltmeter to the battery terminals to measure the voltage Engine Regulator When the engine speed is low the voltmeter reads the battery voltage The voltage increases with an increase in the engine speed although the voltage fluctuation range will be within the specified values If the output voltage is higher than the specified value the rectifier is damaged or the lead is disconnected x If the output voltage does not increase with an increase in the engine speed the rectifier is damaged or the alternator output is insufficient FES02881 Voltmeter for the applied load Rectifier Output Specified Voltage Specified Value Battery Voltage 15 V
39. 0 26 118 mm 1 0283 in FE350 400 26 097 mm 1 0274 in x If the measured value is greater than the service limit replace the balance weight On the FE350 and 400 the bushing can be replaced A Guide Hole B Balance Weight NOTE O To install a new bushing drive it in so that the end face of the bushing is flush with the end face of the balance weight as shown in the diagram on the right A Bushing B Balance Weight e Using a micrometer measure the diameter of the balancer guide in several places Balancer Guide Diameter Service Limit minimum FE250 290 350 400 25 907 mm 1 0593 in Xx If the measured value is smaller than the service limit replace the balancer guide with a new one Reassembly e Make sure to apply fresh engine oil to the sliding and rotating areas 2 Install the balancer on the crankshaft in the following order Balance weight link rod spacer NOTE O Install the spacer with its chamfered end facing the link rod A Balancer Weight B Spacer C Link Rod Uniaxial Rotation Balancer FE170 Disassembly e Remove the crankcase cover and align the matching marks on the balance drive gear of the crankshaft and the balance gear e Take out the balancer shaft from the crankcase Inspection e Inspect the balancer gear for wear or broken teeth x If the gear is excessively worn replace the balancer shaft e Using a micrometer measure the diameter of the balancer journal in several places
40. 0 60 067 mm 2 3648 in FE170 66 067 mm 2 6011 in FE250 76 067 mm 2 9948 in FE290 78 067 mm 3 0735 in FE350 83 067 mm 3 2703 in FE400 87 067 mm 3 4278 in Cylinder Bore Roundness maximum Service Limit 0 56 mm 0 0220 in x If the measurement shows that even one area of the cylinder has a FE309551 greater bore or roundness than the service limit bore the cylinder to an oversize or replace the cylinder block X The oversize piston and piston rings come in 0 50 mm 0 020 in oversize 1 10 mm 0 394 in 2 Center Point 3 8 mm 0 315 in Crankcase Cover Disassembly e Drain the engine oil into an appropriate container e Loosen the crankcase cover retaining bolts in the reverse sequence of the tightening sequence given on the next page Using a hammer or a plastic mallet gently tap on the crankcase cover at the area where the cover is fastened to the engine and remove the crankcase cover A Crankshaft Gear B Camshaft Gear C Timing Mark Reassembly e Clean the mating surface and place a new gasket on it e Apply high temperature grease to the area in which the oil seal lip faces the rotating shaft Apply engine oil to the bearing areas e Verify that the respective timing marks on the crankshaft gear and the camshaft gear as well as on the crankshaft gear and the balancer gear optional equipment on FE170 are properly aligned CAUTION Make sure to remove the oil pump b
41. 0 2138 in 5 415 0 2132 in 0 05 0 002 in 0 5 0 020 in 5 930 0 2335 in 5 915 0 2329 in 0 03 0 001 in 0 6 0 024 in Valve Spring Free Length minimum Intake Exhaust 31 8 1 252 in 32 8 1 291 in Rocker Arm Pushrod Runout maximum Intak Exhaust 0 5 0 020 in 0 3 0 012 in HLA Device Leak Dwon Dimension maximum Intake Exhaust Valve Lift Height by ACR minimum Exhaust Oil Pump Inner Rotor Shaft Diameter minimum Outer Rotor Diameter minimum Width minimum Inner Outer Rotor Clearance maximum Relief Valve Spring Free Length minimum Breather Valve Air Gap maximum 0 2 0 008 in Starter Motor Carbon Brush Length minimum Commutator Diameter minimum Commutator Groove Depth minimum 0 2 0 008 in Refer to Electric Starter System SERVICE DATA 2 7 Service Specifications Service Limit mm Item FE290 FE350 FE400 Type D TypeG TypeD TypeG TypeD Type G Piston Ring Piston Ring Thickness minimum Top Second 1 44 0 057 in e Piston Ring End Gap maximum Top Second 1 2 0 047 in e Oil Ring Visual Inspection E Cylinder Head Valve Seating Surface Width Standard 0 8 0 031 in L Maximum 1 9 0 075 in Valve Guide Bore maximum Intake Exhaust 7 065 0 2781 in Rocker Arm Bearing Bore maximum 12 074 0 4754 in 12 3 0 484 in Gasket Sur
42. 4 49 924 E 1 8474 in 1 9655 in Shaft Runout TIR maximum 0 05 0 0020 in Axial Play maximum 0 35 0 35 0 35 0 013 in 0 013 in 0 013 in standard 0 09 0 20 0 0035 0 0079 in standard 0 08 0 22 0 0031 0 0089 in standard 0 08 0 22 0 0031 0 0087 in Camshaft Camshaft Journal Diameter PTO Side minimum Flywheel Side minimum Cam Lobe Height Intake Exhaust minimum 22 927 29 930 0 9026 in 1 1783 in 22 927 0 9026 in 32 700 1 2874 in 22 927 0 9026 in 34 930 1 3752 in tf 33 240 1 3087 in 22 927 0 9026 in Lt 34 930 1 3752 in SERVICE DATA 2 5 Service Specifications Service Limit mm Item FE290 FE350 FE400 TypeD TypeG TypeD TypeG TypeD TypeG Axial Play maximum 0 35 0 35 0 35 0 06 0 35 0 013 in 0 013in 0 013 in 0 024 0 013 in standard standard standard standard standard 0 07 0 21 0 06 0 24 0 07 0 21 0 06 0 24 0 07 0 21 0 0028 0 0024 0 0028 0 0024 0 0028 0 008 in 0 009 in 0 008 in 0 009 in 0 008 in Connecting Rod Connecting Rod Big End Bore maximum 35 567 37 567 1 4003 in 1 4790 in Connecting Rod Small End Bore maximum 19 051 20 051 0 7500 in 0 7894 in Connecting Rod Bend and Twist maximum 0 15 100 0 006 100 in Dynamic Balancer Balancer Shaft Journal Diameter PTO Side minimum
43. 50 400 Face snap ring side of HLA device upward Governor Shaft arm pivot Snap ring 1 Balancer Guide M6 nut 4 Connecting Rod Gap 12 across flats bolt 2 Crankshaft Remove from to a position where it does not interfere with connecting rod Piston Connecting Rod Assembly Pull it downward from cylinder bore Connecting Rod Remove snap ring and pll piston pin out Snap ring 2 Oil Pump M6 bolt 6 Oil Filter Remove plate M5 bolt 2 Assembly sequence for FE250 290 350 400 Assemble parts in the reverse order of disassembly DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 1 Disassembly Reassembly Inspection and Maintenance Table of Contents trett aech nee ee alte 3 2 Construction and FUNCTION nenn 3 2 Disassembly Cleaning and Reassembly Precau TONS zusehen ieh 3 3 Ls TI 1 tesa en 3 4 Carburetor with Fuel Cutoff Valve 3 6 Governor Mechanism nennen nenne 3 7 Governor Operating Mechanisme 3 7 Governor Gear Assembly Installation 3 8 Governor Arm Installation Setting the Governor 3 8 Allee ica 3 10 Element Cleanimg nos 3 10 Cooling System nennen nennen nen 3 11 Fuel Tank and Elter 3 12 Ignition SyStOmM iis tii nd ee 3 13 Description Of Funcetlon nen 3 13 Spark Inspechon nennen 3 14 Spark Plug Cleaning and Inspection 3 14 Ignition Coil INSPECTION sss sese ee eee eee ee eee 3 15 Igniter Inspection 3 16 Flywheel Disassembly and Reassembly 3 17 Ignitio
44. 6 bolt tank 4 Spark Plug 21 across flats Shroud M6 bolt 6 Muffler Assembly Remove flange retaining nuts M6 nut 2 Remove stay retaining bolt M8 bolt 1 Air Cleaner M5 butterfly bolt 2 Carburetor Tighten it together with air cleaner case M6 nut 2 Governor Arm Control Panel M6 nut 1 M6 bolt 2 Fan Housing Disconnect wire to stop switch M6 bolt 5 FE120 4 Electrical e Ignition Coil FE120 uses M6 bolts M5 bolt 2 e Flywheel M14 nut 1 Cylinder Head e Rocker Case M6 bolt 4 e Cylinder Head Loosen boltss evenly in the reverse M8 bolt 4 order of tightening Valve System e Pushrods Identify intake and exhaust e Rocker Arms Identify intake and exhaust M6 nut 2 e Exhaust Valve Crankcase Cover Loosen bolt evenly in the reverse order of tightening for FE120 M6 bolt 8 for FE170 M8 bolt 7 Camshaft Remove shaft from a position where cam gear marks are aligned Tappets Identify intake and exhaust Governor Shaft Arm Pivot Remove snap ring and pull it out Snap ring 2 of crankcase Connecting Rod Cap 10 across bolt 2 Crankshaft Remove from a position where it does not interfere with connecting rod Piston Connecting Rod Assembly Pull it downward from cylinder bore Connecting Rod Remove snap ring and pull piston pin out Snap ring 2 Assembly sequence for FE120 17 Assembly parts in the reverse order of disassembly SERVICE DATA 2 19 Disassembly Sequence FE250 290 350 400 Bolt to be removed for tool
45. 870 in 0 7846 in 0 6264 in 0 9815 in 0 7845 in 1 1783 in Flywheel Side minimum 14 910 15 910 19 927 0 5870 in 0 6264 in 0 7845 in Cam Lobe Height Intake Exhaust minimum 26 157 30 024 31 040 1 0298 in 1 1820 in 1 2220 in Axial Play maximum 0 50 0 50 0 35 0 35 0 0197 in 0 0197 in 0 0138 in 0 0138 in standard standard standard standard 0 08 0 34 0 08 0 34 0 05 0 23 0 05 0 17 0 0031 0 0031 0 0020 0 0020 0 0134 in 0 0134 in 0 0091 in 0 0067 in SERVICE DATA 2 3 Service Specifications Service Limit mm Item FE120 FE170 FE250 Type D TypeG TypeD TypeG TypeD TypeG Connecting Rod Connecting Rod Big End Bore maximum 26 052 29 052 34 067 1 0257 in 1 1438 in 1 3412 in Connecting Rod Small End Bore maximum 14 042 16 047 18 051 0 5528 in 0 6318 in 0 7107 in Connecting Rod Bend and Twist maximum 0 15 100 0 006 100 in Dynamic Balancer Balancer Shaft Journal Diameter PTO Side minimum 14 943 0 5883 in Flywheel Side minimum 14 933 0 5883 in Weight Guide Hole Bore maximum 26 118 1 0283 in Balancer Guide Diameter minimum 25 907 Link Rod Bearing Bore 1 0200 in Small End Bore maximum 12 057 0 4747 in Big End Bore maximum 47 106 1 8546 in Piston Piston Ring Groove Clearance with new rings Top Ring
46. 9 927 29 930 22 927 0 7845 in 1 1783 in 0 9026 22 927 29 930 22 927 0 9026 in 1 783 in 0 9026 in 22 927 34 930 22 927 BE 0 9026 in 1 3752 in 0 9026 in x If the measured value is smaller than the service limit replace the camshaft with a new one e Using a vernier caliper measure the overall height of the cam of the camshaft Cam Overall Height Service Limit minimum for Intake and Exhaust FE120 26 157 mm 1 0298 in FE170 30 024 mm 1 1820 in FE250 31 04 mm 1 2220 in FE290 32 70 mm 1 2874 in FE350 400 33 24 mm 1 3087 in Xx If the measured value is smaller than the service limit replace the camshaft with a new one Reassembly e Make sure to reinstall the camshaft with the oil pump removed CAUTION If the camshaft is reinstalled with the oil pump attached to it it will cause serious damage to the engine e Place the cylinder block on a base with the flywheel side facing down e Reinstall the tappets or the HLAs in their original positions in accordance with the intake and exhaust identification marks Push the tappets or the HLAs all the way against the cylinder head so that they will not obstruct the installation of the camshaft e With the matching marks of the crankshaft gear and the camshaft gear aligned install the camshaft in the crankcase NOTE O On the FE290 FE350 and FE400 verify that the tab B of the oil pump is securely fitted into the groove A a
47. E O After tightening the bolts make sure that the connecting rod moves easily in the axial direction along the crank pin A Top Ring Gap Position FES08681 B Second Ring Gap Position C Upper Side Rail Gap Position D Lower Side Rail Gap Position E 30 45 Piston Inspection e Clean the carbon deposits off the piston e Using a new piston ring use a gap gauge A to measure the clearance between the ring groove and the ring Piston Ring Groove Clearance Service Limit maximum Top Ring Second Ring FE120 170 250 0 15 mm 0 0059 in 0 12 mm 0 0047 in FE290 350 400 0 16 mm 0 0063 in 0 14 mm 0 0055 in x If the measured value is greater than the service limit replace the piston with a new one AN FES087S1 3 40 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Piston and Connecting Rod e Using an inside micrometer measure the pin hole bore of the piston in several places Piston Pin Hole Bore Service Limit maximum FE120 14 033 mm 0 5525 in FE170 16 033 mm 0 6312 in FE250 18 033 mm 0 7100 in FE290 19 033 mm 0 7493 in FE350 400 20 033 mm 0 7890 in x If the measured value is greater than the service limit replace the piston with a new one FES08881 Piston Pin Inspection e Using a micrometer measure the piston pin diameter in several places Piston Pin Diameter Service Limit minimum FE120 13 975 mm 0 5502 in A FE170 15 975 mm 0 6290 in FE250
48. Flywheel Side minimum Weight Guide Hole Bore maximum 26 118 26 097 1 0283 in 1 0274 in Balancer Guide Diameter minimum 25 907 1 0120 in Link Rod Bearing Bore Small End Bore maximum 12 064 12 057 0 4750 in 0 4747 in Big End Bore maximum 47 126 50 106 1 8554 in 1 9727 in Piston Piston Ring Groove Clearance with new rings Top Ring maximum 0 16 0 0063 in Second Ring maximum 0 14 0 0055 in Piston Pin Hole Bore maximum 19 033 20 033 0 7493 in 0 7887 in Piston Pin Diameter minimum 18 975 19 975 0 7470 in 0 7864 in 2 6 SERVICE DATA Service Specifications Service Limit mm Item FE120 FE170 FE250 TypeD TypeG TypeD TypeG TypeD Type G Piston Ring Piston Ring Thickness minimum Top Second 1 42 0 056 in 1 44 0 057 in Piston Ring End Gap maximum Top Second 1 0 0 039 in Oil Ring Visual Inspection Cylinder Head Valve Seating Surface Width Standard 0 7 0 028 in 0 8 0 031 in Maximum 1 7 0 067 in 1 9 0 075 in Valve Guide Bore maximum Intake Exhaust Rocker Arm Bearing Bore maximum Gasket Surface Warp maximum 5 562 0 2190 in 0 05 0 002 in 6 065 0 2388 in Rocker Arm Shaft Diameter minimum Valve Valve Stem Diameter Intake Valve minimum Exhaust Valve minimum Valve Stem Runout maximum Intake Exhaust Valve Head Thickness minimum Intak Exhaust 5 430
49. G To prevent electrical shock do not hold the spark plug itself Strong spark Does the muffler emit abnormal e Carburetor s low speed fuel Correct smoke adjustment is too rich the number of turns the pilot screw is screwed in When the throttle valve is gradually opened by hand the engine speed decreases or drops suddenly at a certain opening of Carburetor is internally plugged Clean Is air being drawn in through the Yes carburetor s flange surface Flange nuts are loose Retighten e Gasket is damaged Replace Is there appropriate valve through the valve There is a compression leak mida Are the timing gear marks aligned The valve timing is off Correct SERVICE DATA 2 17 Troubleshooting Starter Motor Troubleshooting and Actions e Remove the spark plug cap and ground the high tension lead terminal e Perform an inspection by turning the key switch to the START position CAUTION Do not touch the parts or accessories other than the starter motor when troubleshooting the starter motor If the starter motor does not stop even when the key switch is turned OFF quickly disconnect the negative lead from the battery Starter motor does not spin Does the solenoid click e Battery faulty Recharge or replace e Lead faulty or connected improperly Repair or replace Fuse blown Replace Key switch faulty Repair or replace Solenoi
50. LAS 100 zZ A 4 N Oil Ramp Battery 3 4W DO12V24AH or more The wiring diagrams are common to all models FE201EWS SERVICE DATA 2 11 Wiring Diagram Ignition Coil Igniter Integrated Type For Recoil Starter Model For Electric Starter Model Without oil level Sensor With oil level Sensor of Engine Stop Type IIIT 77 hhh L DEE a N ectifiel gt Spark plug ignitor Sreerag pi L N Control unit D N S N Green Whib N N N N D i y N Black Ep en N rm N dl N Hack Green Red Brown Whita N S T CREE e ly Brown 0FF oro i i y Een RUN oto 7 lt ZIY N Engine switc staat T etek T di Sec atter Ke Je SLALLLEL ALL 2 LL Battery LEARN PRO For Recoil Starter Model For Electric Starter Model With oil level Sensor of Engine Stop Type With oil level Sensor of Alarm Indicator Type Q 77 Z SLA ZZN L e LN N Rectifte tr 7 N Green White Ld N N Black N aen Green White a 8 E C Z N Yellow N 59 Oi L N En E KR GPL 1 P N E i 1 N o x KA Black i A B 1 1 N T See Green Rad RIO le D N Jalolelale N Engine switch mets prr oe Run ero 5 staat otete Oil level sensor Y 7 DAR Br 2 a 2 77207 EN BO12V24AH or more 34W Shown in the hatched frame are those included in The
51. Make sure to install the camshaft before installing the oil pump If the camshaft is installed with the oil pump already in place it will cause serious damage to the engine A Cutout at the End of Camshaft B Protrusion on the Inner Rotor C Oil Filter FE350 400 only FE310951 3 48 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Lubrication System e The reassembly is the reverse order of disassembly e Install the outer rotor and the inner rotor in that order making sure to prevent dust from entering the oil pump CAUTION To install the inner rotor make sure that the protrusion B of the inner rotor properly mates with the cutout A at the end of the camshaft If they are not mated correctly it could cause serious damage e On the FE350 and 400 verify that the oil filter C is securely fitted FE311082 Oil Pump Inspection The oil pressure specification is 31 4 kpa 3 2 kg cm 0 46 psi minimum at the maximum no load speed If the oil pressure is low inspect the oil pump and the relief valve Spring Relief Valve Valve Seat Inner Rotor Outer Rotor Plate Gasket FE311151 Cover Bolt TL DD nm DOOD T e Using a gap gauge measure the minimum clearance between the inner and outer rotors Inner and Outer Rotor Clearance maximum for FE290 350 400 Service Limit 0 3 mm 0 012 in Xx If the measured value is greater than the service li
52. NSPECTION AND MAINTENANCE Valve System HLA Removal CAUTION Always keep the HLA upright with the end of the HLA on which the snap ring is visible facing up socket A faces up If it is placed on its side or upside down the oil that is sealed in the high pressure chamber B could leak out disabling the HLA function CAUTION Do not disassemble the HLA because it is extremely difficult to replenish the oil that is sealed in it e Make sure that the piston is in the top dead center of the compression stroke e Pull the HLA A out towards the cylinder head HLA Inspection If the valve train noise does not go away after the engine is started it could be due to the following reasons e Wear at the clearance between the HLA body D and the plunger G e Debris wedged in the HLA body between the check ball E and the check valve seat O e A drop in the hydraulic pressure of the oil supply path for some reason refer to the section on the Lubrication System NOTE O If debris becomes wedged in the HLA body between the check ball E and the check valve seat O it is structurally unfeasible to perform a repair Therefore it is very important to prevent contamination when changing the engine oil or repairing the engine To inspect the HLA perform a leak down test as follows e Place the HLA with its snap ring facing up on a surface plate and measure the leak down dimension e Using your finger o
53. Rocker Case B Breather C Oil Level Sensor Terminal A Breather Valve B Retaining Screw Breather Valve Air Gap maximum Service Limit 0 2 mm 0 008 in x If the air gap is greater than the service limit or if the breather valve is defective replace the breather valve with a new one A Retaining Screw B Backing Plate C Breather Valve D Air Gap Air Filter cartridge type With the cartridge type oil filter the engine oil change interval can be extended to 100 hours The engine oil must be changed every 50 hours in an engine without the cartridge type filter Ordinarily the engine oil flows in the following order entrance A element B exit C If the element becomes clogged the oil flows through the bypass D thus preventing the engine from operating without oil although the filtering function is bypassed FES11951 FE312151 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 53 Lubrication System Oil Filter Replacement Procedure NOTE O Be careful with hot oil to prevent burns O Always use a genuine Kawasaki oil filter for replacement Other brands of oil filters may also fit but they may be of poor quality e Drain the engine oil into an appropriate container e Remove the oil filter by turning it counterclockwise e Apply oil to the seal E of the new oil filter e Turn the new oil filter clockwise until its seal E comes in contact with n the mating s
54. and pull out the balancer guide from the crankcase D e Remove the connecting rod bolts and the connecting rod cap e Remove the crankshaft from the crankcase If it is equipped with a balancer take out the complete crankshaft assembly as is from the crankcase NOTE O Be careful not to damage the oil seal Crankshaft Crankshaft Gear Governor Drive Gear Balancer Link Rod Balancer Weight Spacer Key Shim T GD nm GOW gt On Type G however the link rod on the crankshaft gear side cannot be disassembled because the crankshaft gear is pressed in FE312382 FE312451 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 55 Crankshaft Crankshaft Inspection e Inspect the crank pin and the journal for galling wear or rust x If the crank pin exhibits damage as described above carefully inspect and repair the big end of the connecting rod or replace the connecting rod or the crankshaft with a new part e Inspect the crankshaft gear for abnormal wear or damaged teeth Xx If the crankshaft gear is worn as described above replace the crankshaft gear with a new one e Using a micrometer measure the diameter of both journals of the crankshaft the diameter of the journal for the balancer link rod and the diameter of the crank pin in several places Xx If the measured value is smaller than the service limit given below replace the crankshaft with a new one FE312551
55. andard Service Limit sd d e FE120 0 0 24 0 0 009 in 0 5 0 0197 in Ee 7 2 0 03 0 30 0 0011 0 0118 in 0 5 0 0197 in Ze lt 0 05 0 17 0 0020 0 0067 in 0 35 0 0138 in CES z 0 09 0 20 0 0035 0 0079 in 0 35 0 0138 in ge Kees z FE350 400 0 08 0 22 0 0031 0 0087 in 0 35 0 0138 in E 7 d o gt EH 7 SEL J 9 gt S LGN E C a ia e g S S EEE L ses da nor E EE Reassembly The reassembly is the reverse order of disassembly e Clean the mating surfaces of the crankcase and the crankcase cover of any residues and install a new gasket e Apply high temperature grease to the lip of the crankcase oil seal Refer to the section on Oil Seal Apply oil to the journals of each part e On the FE221 400 with a reciprocal movement balancer install the reciprocal movement balancer parts on the crankshaft Refer to the section on Balancer e Install the crankshaft in the crankcase making sure not to damage the oil seal lip with the key groove at the tapered area of the crankshaft Measurement B Measurement A DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 57 Balancer Engine vibration is generated primarily by the inertia that is created through the reciprocal mo
56. art 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 AWARNING Always remove the spark plug cap from spark plug when servicing the engine to prevent accidental starting INTERVAL MAINTENANCE Every Every Every Check and add engine oil Check for loose or lost nuts and screws Check for fuel and oil leakage Check battery electrolyte level Check or clean air intake screen Tighten nuts and screws Clean air cleaner foam element X Clean air cleaner paper element Clean fuel filter element Change engine oil without oil filer Change engine oil with oil filer Clean and regap spark plug Change oil filter Replace air cleaner paper element Xx Clean dust and dirt from cylinder and cylinder head fines K Clean combustion chamber K Check and adjust valve clearance K Clean and lap valve seating surface NOTE The service intervals indicated are to be used as a guide Service should be performed more frequently as necessary by operating condition Service more frequently under dusty conditions K Have an authorized Kawasaki engine dealer perform those services GENERAL INFORMATION 1 7 Special T
57. arting poorly due to a compression leak x If the engine is restarted after the HLA has been replaced with a new one the valve could be noisy but the noise will go away after the engine is operated for a while in the medium speed range Valve Clearance Inspection and Adjustment NOTE O Inspect and adjust the valve clearance on a cold engine e Rotate the crankshaft in the normal direction in order to bring the piston to the top dead center of its compression stroke e Using a gap gauge measure the clearance of the intake and exhaust valves e If the clearance differs from the specified value adjust it to the specified value Specified Valve Clearance on Cold Engine GE Intake 0 12 mm 0 005 in Exhaust 0 12 mm 0 005 in e Loosen the lock nut Turn the rocker arm pivot in or out to attain the specified clearance FE120 170 250 On the FE290 use a pair of pliers to hold the adjustment bolt and then loosen the lock nut Turn the adjustment bolt in or out to attain the specified clearance For FE120 170 250 A Rocker Arm Pivot B Rocker Arm C Locknut D Valve E Valve Clearance 3 32 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Valve System e Using a wrench secure the rocker arm pivot and tighten the lock nut to the specified torque Refer to the section on Tightening Torque Specifications On the FE290 use a pair of pliers to hold the adjustment bolt and tighten the lock nut to
58. ber contains carbon deposits _ Clean e Excessive load on engine Correct Engine overheating Refer to section on insufficient engine power output Carburetor flange loose e Cylinder head bolts insufficiently tightened or head gasket burned Retighten Retighten or Replace Engine oil consumption excessive Is compression sufficient Intake valve burned or stuck Replace Flywheel air gap improper Adjust e Carburetor improperly adjusted Correct e Oil ring groove plugged Clean e Oil level too high Correct Valve stem and valve guide worn Replace Governor shaft leaking oil Replace e Oil seal leaking oil Replace Gasket leaking oil Replace Drain plug leaking oil Breather valve faulty Oil viscosity too low Retighten or replace Repair or replace Replace 2 16 SERVICE DATA Troubleshooting Engine runs poorly at low speeds Weak spark Remove a spark plug touch it Spark plug insulation faulty Replace against the engine block and Spark plug electrode fouled Clean crank the engine to check for Igniter faulty separate type Replace sparks Because gasoline in the e Ignition coil faulty Replace form of atomized air fuel mixture e High tension lead faulty Replace is discharged through the spark e Flywheel air gap improper Correct plug hole in the engine at this time place the spark plug as far away as possible from the spark plug hole while making contact WARNIN
59. ce mea surement B e Place these measurements on the crankshaft shim selection table and trace the respective line e Select the next thinner shim that appears on the shim selection table X For example on the FE290 if measurement A is 14 62 mm 0 576 in and measurement B is 16 18 mm 0 637 in the correct shim thickness is t 1 33 mm A Measurement A B Measurement B C Crankcase Cover D Crankcase E Gasket FE3126S1 FE312751 3 56 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Crankshaft FE250 Crankshaft Shim Selection Table SEET ES Unit mm Measurement A PE SS LL UR H H EEE AS LOS HEHE HA Measurement B X For example on the FE350 if measurement A is 15 87 mm and Unit mm FE290 Crankshaft Shim Selection Table 14 80 OY IA H ON ID UL HHAH HZ1 e E me S SS x o S S E 8 Sz L S 2 SE Gs SE SE SE SES E ht 48 Soc ne u SE EEPE Soo ARRARARARHASRSSRSES esegesedsdededidads Measurement B Measurement A FE350 400 Crankshaft Shim Selection Table measurement B is 17 66 mm the correct shim thickness is t 1 53 mm S CT 1 L Bears z ER c 7 R Crankshaft Axial Play Standard and Service Limit maximum unit mm 5 SR SS i B wo DEE Z St
60. ce using a suitable driver which contacts evenly with the side of seal until the face of the seal is even with the end of the hole 13 Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips Before a shaft passes through a seal apply a little oil preferably high temperature grease on the lips to reduce rubber to metal friction 14 Circlip Retaining Ring Replace any circlips and retaining rings that were removed with new ones as removal weakens and deforms them When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more GENERAL INFORMATION 1 3 Before Servicing 15 Cotter Pin Replace any cotter pins that were removed with new ones as removal deforms and breaks them 16 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film During assembly oil or grease whichever is more suitable should be applied to any rubbing surface which has lost its lubricative film Old grease and dirty oil should be cleaned off Deteriorated grease has lost its lubricative quality and may contain abrasive 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 mak
61. control panel to set the engine speed FE300682 to the specified maximum no load speed If the maximum no load speed is specified for a particular piece of equipment follow that specification Maximum No Load Speed Setting 4000 rpm crankshaft NOTE O All adjustments described in steps 1 through 3 must be performed on a warm engine and do not change their adjustment sequence A Pilot Screw B Throttle Lever C Idle Adjustment Screw D High Speed Set Screw E Low Speed Set Screw F Governor Arm G Pivot Arm 3 6 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Carburetor Carburetor with Fuel Cutoff Valve To prevent after burns that occur in the form of combustion in the muffler when the engine is stopped the float chamber of this carburetor is provided with a solenoid actuated fuel cutoff valve When the engine switch is turned to the STOP position the solenoid operates the fuel shut off solenoid valve to stop the flow of the fuel that is supplied to the main jet When the engine switch is turned to the START or RUN position the fuel shut off solenoid valve opens automatically to supply the fuel Inspect the fuel shut off solenoid valve as follows e Remove the fuel shut off solenoid valve by turning it counterclockwise e Keep the tip of the fuel shut off solenoid valve pushed 1 to 2 mm and connect 12 V DC current as shown in the diagram e If the fuel shut off solenoid valve does not retract w
62. ction e Using a cylinder gauge measure the bore of the plain bearing areas of the cylinder block and the crankcase cover Plain Bearing Area Bore Service Limit maximum FE310351 Unit mm Type D Type G Type D Type G FE120 FE170 FE250 FE290 FE350 400 Type D Type G Type D Type G Crankshaft Flywheel Side oylinder block Camshaft 15 063 15 063 16 063 16 063 20 063 0 593 in 0 593 in 0 632 in 0 632 in 0 790 in 30 075 30 075 35 075 35 075 1 184 in 1 184 in 1 381 in 1 381 in 20 063 23 063 23 063 23 063 23 063 0 790 in 0 908 in 0 908 in 0 908 in 0 908 in 15 063 15 063 Balancer Shaft s 0 593 in 0 593 in PTO Sid Crankshaft cates SA 15 063 16 063 20 063 23 063 23 063 amena 0 593 in 0 632 in 0 790 in 0 908 in 0 908 in cover Balancer Shaft Note An empty area signifies that a ball bearing is used If the measured value is greater than the service limit replace the part with a new one 3 46 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Lubrication System Lubrication Method For FE120 170 250 As shown in the diagram on the right the revolution of the crankshaft causes the splash arm that is provided at the big end of the connecting rod to pick up the engine oil from the crankshaft chamber and splash it in a spray form to lub
63. d switch faulty Replace Recharge or replace Repair or replace e Battery drained Lead from solenoid to starter motor faulty or connected improperly Solenoid switch faulty Starter motor faulty Replace Repair or replace Starter motor spins slowly Is the battery fully charged Battery drained Recharge or replace e Lead faulty Lead faulty or connected Repair or replace improperly e Solenoid switch faulty Replace e Starter motor faulty Repair or replace e Engine faulty Repair or replace Yes Starter motor spins but does not crank the engine Is the pinion gear meshing Key switch faulty Replace with the ring gear Solenoid switch faulty Correct Yes Pinion clutch faulty L Replace Starter motor does not stop when the key switch is turned to the off position Does the starter motor stop Pinion gear or ring gear worn Repair or replace when the key switch is e Starter motor adjusted improperly Replace turned to the OFF position e Pinion gear or ring gear faulty Repair or replace Starter motor adjusted improperly Correct Pinion gear returns improperly Repair or replace 2 18 SERVICE DATA Disassembly Sequence FE120 170 Bolt to be removed for tool Disassembly Precaution Name Quantity Drain Plug Warm up engine and drain oil 14 across flats Fuel Tap Fuel Tank Drain fuel before disassembly 17 across flats tap 1 M
64. d Bearing Injection A M H Relief Link Rod Valve Bearing DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 29 Valve System HLA Construction and Operation e When the cam pushes the HLA upward the oil in the high pressure chamber H tries to flow back to the oil pool I of the plunger G by passing through the passage M but because the check ball E closes the passage M the oil cannot flow back and it causes the hydraulic pressure in the high pressure chamber H to rise e The oil of the high pressure chamber H in which the hydraulic pressure has risen leaks little by little through the gap leak down rand between the plunger G and the HLA body D As a result the HLA shrinks slightly and pushes the pushrod P upward e When the rotation of the cam causes the HLA to descend to the cam base circle the pressurized oil from the oil pump passes through the oil hole C in the HLA body D travels through the oil groove N that is cut into the socket F and enters the oil pool I in the plunger G e After filling the oil pool I the oil pushes open the check ball E and flows into the lifter cage J and the high pressure chamber H in order to correct the valve train to achieve zero clearance A Snap Ring B Oil Metering Hole K Plunger L Check Valve Spring O Check Valve Seat P Pushrod FE308582 FEIOSEWZ 3 30 DISASSEMBLY REASSEMBLY I
65. d and cannot be disassembled e Aseparate type cooling fan can be assembled by aligning the concave portions along the circumference of the fan with the magnets on the flywheel e Clean the cooling fan blades if they have debris or dust on them e If the fan blades are damaged replace the cooling fan with a new one A Convex Area of Cooling Fan B Mgnet Portion C FE120D AB00 only 3 12 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Fuel Tank and Filter e Place an appropriate container under the fuel filter to catch the fuel Remove the filter pot turn the fuel tap ON and completely drain the fuel from the fuel tank and the fuel line If the drained fuel contains dust or water the fuel line from the fuel filter to the carburetor must be inspected and cleaned CAUTION Gasoline is extremely dangerous due to its high volatility Han dle it away from sparks or fire and ensure proper ventilation e If the fuel tank is deformed cracked or rusted replace it with a new one e After draining the fuel from the tank pour a cleaning solvent into the tank and shake it well Discard dust and sediments together with the cleaning solvent e Using compressed air thoroughly dry the inside of the fuel tank and the fuel filter before installing them e Make sure that the fuel gauge operates smoothly and replace it with a new one if it is defective e Inspect the breather hole in the tank cap and the air
66. e The reassembly is the opposite of the disassembly e Apply engine oil to the valve stem before reassembling the valve A Spring Retainer B Side Hole C Sliding Direction F Fes062s1 FE306351 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 33 Valve System For FE250 290 350 400 Disassembly e Use a valve spring compressor to compress the valve spring and remove the collet e Remove the valve spring compressor e Remove the retainer valve spring and valve e If the stem seal that is provided on the intake side of the FE290 350 or 400 is damaged replace the stem seal with a new one NOTE O Do not remove the stem seal unless it is necessary to do so y Intake A Valve Spring Compressor B Collet C Retainer D Valve Spring E Stem Seal F Spring Seat FE306451 Reassembly e Verify that the valve seat is making proper contact and that the valve stem moves smoothly in the guide e The reassembly is the opposite of the disassembly e Apply engine oil to the valve guide and the lip of the valve stem seal before reassembling the valve FE306551 Valve Guide Inspection e Use a bore micrometer to measure the bore of the valve guide Valve Guide Bore Service Limit maximum for both Intake and Exhaust FE120 5 562 mm 0 2190 in FE170 5 562 mm 0 2190 in FE250 6 065 mm 0 2388 in FE290 350 400 7 065 mm 0 2782 in Xx If the measured value exceeds
67. efore installing the en camshaft Serious damage to the engine will result if the camshaft is installed with the oil pump in place A Crankshaft B Timing Mark C Balancer Gear 3 44 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Cylinder Block and Crankcase Cover e Verify that a crankshaft or the camshaft that requires an axial play adjustment shim is provided with an adjustment shim Refer to the section on Axial Play Adjustment e Verify that the governor weight is closed Also verify that the governor arm is positioned so that its front receives the end of the governor sleeve Refer to the section on Governor Mechanism e Install the crankcase cover while paying attention to the meshing of the governor gear evenly tighten the retaining bolts in the sequence given in the diagram and tighten them to the specified torque Refer to the section on Tightening Torque Specifications FE309851 FE309951 FE310051 Ball Bearing e The table below lists the areas in which ball bearings are used An empty area signifies that the case acts directly as a plain bearing Ball Bearing Areas and Nominal Numbers FE120 FE170 FE250 FE290 FE350 400 Crankshaft 6204 6305 6305 6206 6206 Balancer Shaft Crankshaft 6204 6204 6205 6205 6206 6206 6306 6306 6207 6207 PTO Side Camshaft 6204 6205 6206 6306 6207 Balancer Shaft 6202 6202 Note
68. er link rod on the PTO side cannot be disassembled because the crankshaft gear is pressed in Inspection and Repair e Using a micrometer measure the bearing bore of the big and small ends of the link rod in several places Link Rod Bearing Bore Service Limit maximum Unit mm Small End Bore Big End Bore FE250 12 057 0 4747 in 47 106 1 855 in FE290 12 064 0 4750 in 47 126 1 855 in FE350 400 12 057 0 4747 in 50 106 1 973 in A Link Rod Big End Bearing Bore B Small End Bearing Bore Xx If the measured value is greater than the service limit replace the link rod On the FE290 the bushing can be replaced Replace the link rod bushing as follows e Support the big end of the link rod as described in the diagram and use a driver to pull the bushing out A Bushing Driver B Bushing C Link Rod D Tool Base e Wash the disassembled parts and allow them to dry e Apply engine oil to the new bushing e Using a bushing driver install the bushing so that the gap of the bushing is positioned as shown in the diagram Drive the bushing so that it is 1mm deeper than the end face of the link rod A Depression B Bushing Gap FE313251 FE313451 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 59 Balancer e Using a micrometer measure the balancer guide hole bore of the balance weight in several places Balancer Guide Hole Bore Service Limit maximum FE250 29
69. er to R x 100 N and measure the resistance Individual Igniter Resistance KO Tester negative Tester positive terminal Case A Terminal B 0 1 1 0 Terminal Case A Terminal B x If the measured value differs from the above replace the igniter Igniter with Oil Warning Light Measurement e Set the measurement range of the hand tester to R x 100 2 in order to measure the resistance at the areas given in the table below Igniter with Oil Warning Light Resistance KO Tester Negative Tester Positive Terminal C black 0 1 1 0 Terminal D brown C black E yellow x If the measured value differs from the table above replace the igniter Xx To inspect the oil warning light LED refer to the section on the lubrication system A Igniter B Oil Warning Light C Primary Terminal D Ground Terminal E Oil Level Sensor Terminal CDI Igniter Measurement e Set the measurement range of the hand tester to Rx1002 in order to measure the resistance at the areas given in the table below X If the measured value differs from the table above the igniter is defective and it must be replaced CDI Igniter Resistance FE302151 FE302251 ir Black Yellow Grey Light Green Red FES02381 2 Tester Tester Positive Terminal Negative S E d Light Green Black Yellow Te Black erminal ack s
70. erminals A and B increases When the flywheel reaches the position of the ignition timing signal base current IB2 flows from automatic ignition advance circuit C to transistor TR2 At that instant the current changes into collector current IC2 which is amplified by transistor TR2 e In the meantime because the internal resistance of TR2 is consider ably lower than TR1 IB1 that was flowing through TR1 until then will turn into IC2 thus changing its direction to flow via TR2 e In this manner base current IB1 of TR1 will not momentarily flow thus causing large current IC1 that was flowing between terminals A and B until then to stop suddenly e Due to the sudden change in the current in the primary circuit a high voltage is generated in secondary side F causing spark plug G to spark A B Igniter Terminal C Automatic Ignition Advance Circuit E Primary Coil F Secondary Coil G Spark Plug FE301692 ESW Engine Switch FE301782 3 14 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Ignition System Automatic Ignition Advance Device This device enables the engine to achieve appropriate ignition timing in all speed ranges The ignition timing must be retarded slightly when the engine is started and at the low to medium speed range On the other hand the ignition timing must be advanced in the high speed range in order to generate the sparks early on because the intervals of the air fuel mixtu
71. es reference to molybdenum disulfide grease MoS2 in the assembly of certain engine parts Always check manufacturer recommendations before using such special lubricants 17 Electrical Wires All the electrical wires are either single color or two color and with only a few exceptions must be connected to wires of the same color On any of the two color wires there is a greater amount of one color and a lesser amount of a second color so a two color wire is identified by first the primary color and then the secondary color For example a yellow wire with thin red stripes is referred to as a yellow red wire it would be a red yellow wire if the colors were reversed to make red the main color Wire cross section Name of Wire Color Red Wire Strands Yellow Red Yellow Red 18 Replacement Parts When there is a replacement instruction replace these parts with new ones every time they are removed There replacement parts will be damaged or lose their original function once removed 19 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure 20 Specifications Specification terms are defined as follows Standards show dimensions or performances which brand new parts or systems have Service
72. face Warp maximum 0 05 0 002 in Rocker Arm Shaft Diameter minimum 11 949 0 4704 in Valve Valve Stem Diameter Intake Valve minimum 6 930 0 2728 in E Exhaust Valve minimum 6 915 0 2722 in E Valve Stem Runout maximum Intake Exhaust 0 03 0 001 in Valve Head Thickness minimum Intak Exhaust 0 6 0 024 in Valve Spring Free Length minimum Intake Exhaust 32 8 1 291 in 38 1 1 500 in Rocker Arm Pushrod Runout maximum Intak Exhaust 0 3 0 012 in 0 5 0 02 in HLA Device Leak Dwon Dimension maximum Intake Exhaust 0 5 0 02 in Exhaust 0 6 0 024 in 1 0 0 039 in Oil Pump Inner Rotor Shaft Diameter minimum 12 627 0 4971 in Outer Rotor Diameter minimum 40 467 1 5932 in Width minimum 9 920 0 3906 in Inner Outer Rotor Clearance maximum 0 3 0 012 in e Relief Valve Spring Free Length minimum 19 0 0 748 in Breather Valve Air Gap maximum 0 2 0 008 in Starter Motor Carbon Brush Length minimum 2 Commutator Diameter minimum id Commutator Groove Depth minimum 0 2 0 008 in e Refer to Electric Starter System 2 8 SERVICE DATA Adjustment Specifications Adjustment Specifications Item FE350 FE120 FE170 FE250 FE290 FE400 Idle Speed Setting crankshaft 1600 rpm 1300 rpm No Load Maximum Speed Setting crankshaft 000 Hem Valve Clearance Intake Exhaust Gran EE Adjus
73. filter plugged with dust or air e Air hole in tank cap plugged e Fuel line in carburetor plugged Replace Correct Replace Add Clean Clean Clean Choke used excessively Air cleaner plugged Fuel level in float bowl too hiah Piston piston rings worn e Piston rings stuck e Cylinder bore worn Cylinder head bolts insufficiently tightened Valve seat faulty contact e Plunge up by valve e Cylinder head warped Valve spring broken e Valve stuck e Cylinder head gasket burned Plunge up of HLA device on FE350 or FE400 Open Clean Replace Replace Clean or replac Bore or replace Retighten Lap Lap Correct Replace Replace Clean or grind Replace Await proper operation time 2 14 SERVICE DATA Troubleshooting Insufficient engine power output Yes Adjust load Adjust Clean Is the engine overheating Excess load on engine Carburetor incorrectly adjusted e Cooling air inlet or cylinder fins clogged with dust e Combustion chamber contains carbon deposits Spark plug faulty Clean Replace Is there proper lubrication e Oil in crankcase excessive or Correct insufficient e Oil excessively dirty Replace Does the muffler emit Air cleaner plugged Clean abnormal smoke e Exhaust port and muffler contain Clean carbon deposits Carburetor improperly adjusted Adjust e Oil in crankcase excessi
74. g in a leaner air fuel mixture Setting the fuel level to high increases the volume of fuel that is drawn up to the venturi resulting in a richer air fuel mixture A Main Jet B Main Nozzle C Main Air Jet body jet D Chocke Valve E Throttle Valve F Float Hinge Pin Pilot System FE300182 coe Air Fuel Mixture FE300253 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 3 Carburetor An optimal fuel level is prescribed at the time the carburetor is designed Along with the fluctuations in the fuel level the float moves up and down in order to open and close the float valve The flow of fuel into the float chamber is enabled or stopped in this manner in order to maintain the fuel level at the prescribed level Float System CAUTION The fuel level of the carburetor of the FE series engines cannot be adjusted Replace the float if it is defective The air pressure in the float chamber is constantly maintained at Berges atmospheric pressure via the air vent A Float B Float Valve C Air Vent D Float Chamber Disassembly Cleaning and Reassembly Precautions e Here are the instructions for removing and reinstalling the link rod and the linkage spring that connect the carburetor to the governor arm With the carburetor mounted on the engine insert a flat blade screwdriver between the throttle lever at the carburetor and the link rod and gently twist the
75. h Holder Brush Spring Brush Yoke Assembly Shift Lever Armature Washer Stopper Snap Ring Clutch Assembly Front Cover oo ch 022 ch ch 4 OO P GM A OH 3 22 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Starter System Snap Ring Collar Spring Clutch Assembly Nut Spring Washer Bolt Rear Cover Washer Brush Holder Brush Spring Brush Yoke Assembly Armature Washer Front Cover 0 Q GW E KA M ZA dd dd OO P GM A OH Solenoid Starter Motor Wiring Inspection Although the following procedure gives the steps for inspecting the shift lever type starter motor it can also be applied to the Bendix type by replacing the word solenoid with solenoid switch NOTE O First check the battery and make sure that it is fully charged e Detach lead A from the solenoid terminal of the starter motor and keep it away from the solenoid terminal e Detach lead B that connects the key switch to the solenoid set the measurement range of the tester to DC25 V and connect it to lead B and a ground on the unit Turn the key switch to the START position and read the voltage on the tester x If the voltage is O or lower than the battery voltage inspect the key switch and the wiring Refer to the switch section of the Ignition System x If the voltage is the same as the battery voltage it is normal e Set the measurement range of the tester to Rx1 N
76. han the service limit replace the rocker shaft A Rocker Shaft Pushrod Inspection e Support both ends of the pushrod on V blocks and place a dial gauge against the center e Gently rotate the pushrod to measure its bend through the fluctuation of the dial gauge Pushrod Bend for both Intake and Exhaust FE290 170 0 5 mm 0 020 in FE250 290 0 3 mm 0 012 in FE350 400 0 5 mm 0 020 in FE307551 FE307651 FESO77S1 FE307851 FE307951 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 37 Piston and Connecting Rod Disassembly e Drain the engine oil into an appropriate container e Remove the retaining bolts from the crankcase cover Using a wooden or a plastic mallet gently tap on the crankcase cover at the area where the cover is fastened to the crankcase and remove the crankcase cover Refer to the section on Crankcase Cover Disassembly e Refer to the section on Camshaft Disassembly and remove the camshaft and the tappet When working on the FE170 that is equipped with a uniaxial rotation balancer remove the balancer e Turn the crankshaft to a position in which the cap bolt A is easily SERA visible e Remove the two cap bolts and remove the connecting rod cap B e Push the big end of the connecting rod towards the cylinder head and push out the piston and connecting rod assembly NOTE O Clean off the carbon from the cylinder bore before pushing out
77. hen the power is connected the solenoid is defective In this case the fuel shut off solenoid valve must be replaced NOTE O To enable the shut off solenoid valve to retract the tip of the shut off solenoid valve must be pushed slightly A Shut off Solenoid Valve B Solenoid A wiring diagram for the carburetor with a fuel shut off solenoid valve is shown on the right Engine Spark Plug Ignition Coil ACD Igniter Separate type Carburetor Fuel Shut off Solenoid Valve Key Switch Regulator Fuse Battery Starter Motor Z X CL L GD Hm O OW T FE300782 Keep it pushed 1 or2mm 0 039 0 079 in INNEN CH L L AlslcIole Sales RUN oT START ot FE 10 82 6 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 7 Governor Mechanism Governor Operating Mechanism Connected to the throttle lever on the carburetor via a link rod the governor operates automatically in accordance with load fluctuations in order to maintain a constant engine speed The governor relies on centrifugal force for its operation When the engine speed increases the governor weight which is attached to the governor gear that is meshed to the crankshaft gear opens outward by centrifugal force This movement pushes the sleeve outward which moves the governor lever in the direction to close the throttle valve Conversely when the engine speed decreases the
78. ice Limit FE120 170 0 7 mm 0 028 in 1 7 mm 0 067 in FE250 290 350 0 8 mm 0 031 in 1 9 mm 0 075 in e USA a 45 30 only for the intake on FE350 and 400 valve seat cutter apply a light force to remove the burrs from the seat e Use a marker blue ink on the valve seat to inspect the contact between the valve and the valve seat The valve and the seat must make contact in the center of the contact surface along the entire circumference as shown in the diagram e If the contact width is inadequate cut the seat again and lap the valve Rocker Arm and Rocker Shaft For FE120 170 250 e l abnormal wear is present on the ball surface of the rocker arm or the surface that comes in contact with the valve stem and the pushrod replace the rocker arm with a new one For FE290 350 400 e Using an inside micrometer measure the bore of the rocker arm bearing in several places Because the rocker arm of the FE350 and 400 is made of sheet metal use a vernier caliper to measure its bore 1 Ball surface of rocker arm Rocker Arm Bearing Bore Service Limit maximum FE290 12 074 mm 0 4754 in FE350 400 12 3 mm 0 4843 in x If the measured value is greater than the service limit replace the rocker arm e Using a micrometer measure the diameter of the rocker shaft in several places A Rocker Arm Rocker Shaft Diameter Service Limit minimum FE290 350 400 11 949 mm 0 4704 in Xx If the measured value is smaller t
79. in Ib 1 0 7 2 2 10 SERVICE DATA Wiring Diagram Ignition Coil lgnition Separate Type For Recoil Starter Model Without oil level Sensor For Electric Starter Model With oil level Sensor of Engine Stop Type N NULLLLLL Lo I LLLL 2 For Recoil Starter Model With oil level Sensor of Engine Stop Type S ITIITI DIA TA Ges ZN Spark plug Oo IN BE Yellow N E N N UT ignitor ignition coil N S CS N rown N N E Black Yellow N N N LU N N ch Eo ER N Black N af N Brown D Engine switch Y 1 N N i D N PE DINA Shown in the hatched frame are those included in the standard equipment A LILA RA 77 SCH VISTI TN Md DIZE DR RARA EE N N Spark plug oi N Spark plug S mo 7 ignitor N us N N ignition coil Ld U N ignition coil N N g g N N Ni N N y N N N N 2 E y d N Key switch SI N N i pS 1 1 d oo N N N Brown A N Green Red Swab Te a Te l l Engine switch N DEF odo SR Se i H N RUN N E East L f N VA batey NADIA For Electric Starter Model With oil level Sensor of Alarm Indicator Type OOLLOP OPE ET hid hts Spark plug Ignition coil Green White Oi Bo T i I Key switch D H H H j Green Red l fl E albleld e EN
80. inder head and replace the gasket with a new one e Place the pushrods in their original positions in the cylinder block and install the cylinder head At this time make sure that each end of a pushrod is properly fitted in the recessed area of the tappet and the rocker arm e Tighten the cylinder head retaining bolts little by little evenly in accordance with the tightening sequence given in the diagram on the right to their specified torque Refer to the section on Tightening Torque Specifications 5 A EIN Ch A Gr FE305281 3 28 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Valve System Hydraulic Lash Adjuster HLA The FE350 and 400 are equipped with a Hydraulic Lash Adjuster HLA to automatically adjust the valve train to zero clearance through hydraulic means Purpose of the HLA The HLA hydraulically adjusts the valve train to zero clearance by automatically absorbing the changes in the clearance that are created through thermal expansion or wear The purpose of the HLA is to eliminate the need to adjust the clearance of the valve train reduce the noise generated by the valve train and stabilize the performance of the engine HLA Position and Oil Supply Path The HLA needs the pressurized oil from the oil pump The diagram shows the position in which the HLA is installed and the oil supply path FE30S382 FE305451 F Link Rod Bearing G Connecting Ro
81. ing Rod Inspection en 3 41 Cylinder Block and Crankcase Cover 3 43 Cylinder Inspection 3 43 Crankcase Cover 3 43 EERSTEN 3 44 Oil Se al iii 3 45 Plain Bearing Area Inspection uneeee 3 45 Lubrication SySteM nennen 3 46 Lubrication Method 3 46 Oil Pump Disassembly and Reassembly 3 47 Oil Pump INSPECTION eee eect eee eee eee ee eee 3 48 Oil Level Warning Device AAA 3 49 EI TEE 3 52 Air Filter cartridge Ype sese ee ee eee 3 52 CC EE 3 54 Disassembly ccoo 3 54 Crankshaft Inspection 3 55 Crankshaft Axial Play Adjustment 3 55 REASSEMDIY uk 3 56 ENEE 3 57 Reciprocal Movement Balancer FE400 350 290 OO ad dit 3 58 Uniaxial Rotation Balancer FE170 3 59 Camshafts een 3 61 Disassembly ei acc tain ihe inet es 3 61 INSPOCHON eege iii 3 61 REASSEMDIY uk 3 62 Camshaft Axial Play Adjustment 3 63 3 2 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Carburetor Construction and Function The function of a carburetor is to mix fuel and air by applying the principle of an atomizer thus creating an appropriate air fuel mixture in accordance with load fluctuations The major functions of a carburetor consist of the following four systems Pilot System The function of this system is to supply fuel during the idling and the low speed light load operating conditions The fuel that is regulated by the pilot jet mixes with the air that is reg
82. mit replace the rotors as a set A Gap Gauge FES11251 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 49 Lubrication System e Using a micrometer measure the following parts Inner Rotor Shaft Diameter maximum for FE290 350 400 Service Limit 12 627 mm 0 4971 in Outer Rotor Diameter maximum for FE290 350 400 Service Limit 40 467 mm 1 5932 in Outer Rotor Width maximum for FE290 350 400 Service Limit 9 920 mm 0 3906 in A Even if one of the measured values is smaller than the service limit replace the rotors as a set A Innter Rotor Shaft Diameter B Outer Rotor Diameter C Outer Diameter Width FES11351 e Inspect the relief valve and the valve seat contact area and repair or replace it with a new one if any abnormal condition is present e Using a vernier caliper measure the free length of the relief spring Relief Spring Free Length maximum for FE290 350 400 Service Limit 19 0 mm 0 75 in Xx If the measured value is smaller than the service limit replace the spring A Valve Seat B Relief Valve C Spring FES 14St Oil Level Warning Device The oil level warning device is incorporated in the electronic ignition circuit It consists of the following parts A Igniter LED with oil warning light separate type Controller LED with oil warning light intergrated type B Ignitioi Coil C Flywheel D Ignition Plug E Oil Level Sensor Switch
83. n Coil Reassembly Air Gap Adjustment 3 18 Key Switch engine switch Inspection 3 18 Charging Gvstem nennen 3 19 Charging System Inespechon eee ee ee ee eee 3 19 AGG Inspection EE ia iii 3 19 Rectifier INSPECTION nennen 3 19 Regulator Inspecton nennen 3 20 Starter System unnsnesenssennnennnnnnnnnennnnnnnnnnnnnnnn non 3 21 Starter Motor Construchlon nn 3 21 Solenoid Starter Motor Wiring Inspection 3 22 Starter Motor Inspecton nennen 3 23 Recoil T TT 3 25 Disassembly kA 3 25 Reassemply nenn 3 25 Cylinder Head ico re 3 26 Compression Inspechon nennen 3 26 Disassembly 2 mens ee 3 26 Cleaning and Inspection 3 27 REASSEMDIY nenn 3 27 Valve System zunssnsserssersnnnnnnrnnonnnennnnnnnnn nennen nen 3 28 Hydraulic Lash Adjuster HL A 3 28 Valve Clearance Inspection and Adjustment 3 31 Automatic Compression Release ACR Device In Geet 3 32 Valve Disassembly and Reassembly 3 32 Valve Guide Inepecton nennen 3 33 Valve Inspection u uzerssersserseersnnrnnennnennnnnnnn nen 3 33 Valve Spring Inspection 3 34 Valve Seat Inspection and Lapping 3 35 Valve Seat CGorrechon nennen 3 35 Rocker Arm and Rocker Shaft cesses 3 36 Pushrod Inspection 3 36 Piston and Connecting Rod AA 3 37 Disassembhy nennen nennen 3 37 Reassembly uk 3 37 Piston INSPECTION nennen 3 39 Piston Pin Inspection 3 40 Piston Ring Inepecton een 3 40 Connect
84. n Coil Resistance Measurement If a coil tester is unavailable use a hand tester P N 57001 1394 to measure the internal resistance of the coil Although this test is not sufficient to determine the integrity of the coil it will serve as a criterion for making a judgment e Connect the hand tester as shown in the diagram on the right set it to the measurement ranges listed in the table below and measure the resistance values 2 Ignition Coil Internal Resistance separate igniter type Ignition Coil Internal Resistance separate igniter type Q Measurement Area Measurement Range Resistance Primary Coil Rx 1 0 6 1 10 Secondary Coil Rx1k 6 0 10 0 k Ignition Coil Internal Resistance integrated igniter type Q Measurement Area Measurement Range Resistance Primary Coil Rx 1 0 6 1 4 Secondary Coil Rx1k 6 0 11 0k x If the measured value is within the range given above or greater the coil is normal If the measured value is lower than the above the coil is defective and it must be replaced with a good one 1 Measurement of Primary Coil Resistance 2 Measurement of Secondary Coil Resistance 3 Ignition Coil 3 16 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Ignition System Igniter Inspection Measure the internal resistance of the igniter Individual Igniter Inspection e To test the individual igniter shown in the diagram on the right set the measurement range of the hand test
85. ng Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them evenly in a staggered sequence This is to avoid distortion of the part and or causing gas or oil leakage Conversely when loosening the bolts nuts or screws first loosen all of them by about a quarter of a turn and then remove them Where there is a tightening sequence indication in this Service Manual the bolts nuts or screws must be tightened in the order and method indicated 4 Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench 5 Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removal of screws held by a locking agent in order to avoid damaging the heads 6 Edges Watch for sharp edges especially during major engine disassembly and assembly Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over 7 High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent commonly
86. ommutator Groove Depth Standard 0 5 0 8 mm 0 020 0 032 in Service Limit 0 2 mm 0 008 in e A Segment B Insulation Portion FES04281 C Groove Depth DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 25 Recoil Starter CAUTION The recoil spring is stored in the reel under high tension Hold it firmly when handling so that the spring does not jump out Disassembly e Pull the rope out approximately 350 mm and tentatively tie a knot at that position e Pull out the knot of the rope that is pushed into the recess in the handle undo the knot and remove the handle e While holding the reel with your hand undo the knot of the rope and pull the rope out through the hole in the case Hook the rope on the cutout of the reel and slowly allow the reel to retract in a direction that will relieve the tension of the coil spring e Remove the retaining screw from the center of the reel and remove o the parts while making sure not to allow the recoil spring to jump out D FE304381 77 e To remove the recoil spring make sure that the tension of the spring has been completely relieved Then remove the reel by carefully pulling the reel straight up The recoil spring remains retracted in the reel or spring case e During the removal of the recoil spring carefully separate it from the reel while retracting it outward from the center of the spring NOTE O On the FE120 170 250 290
87. ools Compression Gauge 57001 221 Piston Ring Compression Grip 57001 1095 Piston Ring Compression Belt 50 67 57001 1096 Kawasaki Bond Silicone Sealand 56019 120 Piston Ring Compression Belt 67 79 57001 1097 Piston Ring Pliers 57001 115 Piston Ring Compression Belt 680 691 57001 1320 1 8 GENERAL INFORMATION Exploded View FE120 GENERAL INFORMATION 1 9 Exploded View FE170 FE 02 W5 G 6116 EL v076 L e v si19L AL Ee 56026 A vo d V S 106 O A LAS posp 0062 veroez L t geioez 91802 6 COR YE L5 09150 3 18026 z K H ize celos D 1 10 GENERAL INFORMATION Exploded View FE250 TALIS v 20088 OU 9e0zh ocize YILL9L gozze iie YLLO9Z E 20026 08012 LE LLE YsL026 Is v18095 108095 gt gt RR 22076 DEN Seit 8 8026 860076 1 ES ES 80 095 vocoss a aous 06126 110218 ioi 02167 TAY A vos ze os 0112 CR veroze De 60076 60026 HAD LIE D IL g Dr e SE d Ir lt i St L I FE 03 GENERAL INFORMATION 1 11 Exploded View FE290 40080 7 S E 92170 A 181714 6 un os
88. pping A prerequisite for inspecting the valve seat contact is that the valve guide and the valve stem are normal e Apply a thin layer of fine lapping compound on the contact surface of the valve e Using a lapper A lap the valve against the seat by rotating the valve e Pull out the valve and inspect whether there is an even contact at the valve seat along its entire circumference If not lap the valve and the valve seat e Lap 8 to 10 times and inspect the contact each time Repeat this process until there is contact along the entire circumference e After completing the lapping completely wash off the compound from all parts and allow the cylinder head to dry A Lapper 1 Valve Seat Contact Width FESO71S1 AZ FE307251 FE307351 Valve Seat Correction If the contact width of the valve seat is nearing the service limit or there are small depressions or wear on the valve seat correct the valve seat e Using a 45 30 only for the intake on FE350 and 400 valve seat cutter apply a light force to smoothly cut the valve seat to create a concentric circle e Using a 30 15 only for the intake on FE350 and 400 valve seat cutter make a shallow cut so that the valve seat contact A will have the standard width FE307451 3 36 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Valve System Valve Seat Contact Standard Width and Service Limit minimum for both Intake and Exhaust Standart Serv
89. r a rod with a rounded tip firmly press the socket A down Measure the extent of the recess of the socket A which is the leak down dimension e If the leak down dimension is greater than the service limit replace the HLA with a new one HLA Leak Down Dimension maximum Service Limit 0 5 mm 0 002 in FE305751 j FE305851 FE305951 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 31 Valve System HLA Reassembly e Make sure that the piston is at the top dead center of the compression stroke CAUTION Make sure to apply engine oil to all the sliding areas of the HLA pushrod rocker arm rocker shaft and valve before reassembly e Insert the HLA with its end on which the snap ring is visible facing up from the cylinder head side of the engine block e Mate the tip of the pushrod to the recess in the HLA and the other end with the recess in the rocker arm and install the cylinder head Pushrod Rocker Shaft Rocker Arm Valve HLA Engine Block Cylinder Head Onm FE306082 HLA Operation Precaution The HLA comes filled with low viscosity oil Once the engine starts the low viscosity oil is gradually replaced with the engine oil xk After an engine that has previously operated is rebuilt the valve takes approximately 20 minutes to seat itself Therefore start a rebuilt engine 20 minutes after it has been rebuilt This prevents the engine from st
90. re ignition and expansion are shorter The diagram on the right shows the relationship between the crankshaft speed and the ignition timing degrees before the top dead center of the automatic ignition timing device of the FE series Spark Inspection Check for sparks as follows e Remove the spark plug connect it to the plug cap that is attached to the high tension lead and place the spark plug in contact with the engine block When doing so place the spark plug as far away as possible from the spark plug hole and make contact at an area that does not contain gasoline CAUTION Perform the spark inspection after making sure that there is no presence of gasoline in the area in order to prevent unintended ignition e Turn the stop switch or the key switch ON to turn the crankshaft and check if sparks are generated at the electrode of the spark plug x If there are no sparks or the sparks are weak clean the spark plug adjust the spark plug electrode gap to between 0 7 and 0 8 mm and check for sparks again If there are no sparks or the sparks are weak even after cleaning the spark plug and adjusting its electrode gap replace the spark plug with a new one and check for sparks again x If there are no sparks or the sparks are weak even after installing a new spark plug inspect the ignition system Spark Plug Cleaning and Inspection e Using a wire brush remove the carbon deposits from the spark plug If the spark pl
91. ricate the internal parts Forced splashing type For FE290 350 400 A forced pumping lubrication method through the use of an oil pump has been adopted Forced pumping type The oil pump draws in the oil and pumps the oil through the oil passages described below The oil pump is provided with a relief valve at its outlet side When the oil pressure is higher than the preset pressure of the relief valve the relief valve opens to discharge the oil into the crankcase When the oil pressure is lower than the preset pressure the relief valve closes If the oil pressure becomes excessively high it could break the seal in the oil passage critically damaging the engine For the oil passage on the FE350 and 400 refer to the following section Valve System HLA FE310451 FE310882 FE310651 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 47 Lubrication System L J K Ea os Gees Em Bearing B C D E F Filter Oil Pump Passage an hat Fink Rad Bearing Bearing Cartridge ME Connecting Filter L Rod Bearing A Oil Pool Injection i Oil Pump Disassembly and Reassembly Disassembly e Remove the six retaining bolts from the oil pump cover and remove the oil pump cover gasket and plate in that order A Retaining Bolts B Oil Pump Cover e Remove the inner rotor and outer rotor in that order A Inner Rotor B Outer Rotor Reassembly CAUTION
92. rom the crankcase NOTE O After removing the tappet place marks on them to identify the intake and exhaust tappets so that they can be reinstalled in their original positions Keep the end of the HLA in which the snap ring is visible upright If it is placed on its side the oil that is sealed in the unit could leak out disabling the HLA function A Matching Marks Inspection e Inspect the camshaft and cam gear for any broken teeth or wear X If they are abnormally worn or have broken teeth replace the camshaft with a new one e Inspect the camshaft to make sure that its automatic compression Reduction ACR function operates smoothly and does not have any damage or abnormal wear X When the weight C is closed if the top of the arm A is lower than the base B replace the ACR with a new one When the weight C is pulled entirely outward with your finger if the top of the arm A is higher than the cam base B replace the ACR with a new one Xx If ACR parts are worn replace the ACR with a new one FES14331 3 62 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Camshaft e Using a micrometer measure the camshaft journal in several places Camshaft Journal Diameter Service Limit minimum Unit mm PTO Side Flywheel Side Type D Type G Type D G 14 910 19 930 14 910 0 5870 in 0 7846 in 0 5870 in 15 910 24 930 15 910 0 6264 in 0 9815 in 0 6264 in 1
93. sistance at the areas given in the table below e Although this test is not sufficient to determine the integrity of the regulator it will serve as a criterion for making a judgment Regulator Internal Resistance KO Tester Negative gt Terminal Tester Positive Terminal B 10 50 1 5 15 75 4 20 4 20 Sa x If the measured resistance differs from the table above replace the regulator A Key Switch B Charging Indicator Light FESO31S1 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 21 Starter System Starter Motor Construction An FE series engine comes with a Bendix type or shift lever type starter motor The electrical circuit of a starter motor consists of a key switch engine switch solenoid or solenoid switch on the Bendix type battery and starter motor A Starter Motor B Key Switch C Battery D Solenoind FE303251 With the shift lever type turning the key switch to the START position causes a small amount of current to flow to the solenoid which actuates the plunger which in turn moves the shift lever in order to engage the pinion gear of the starter motor with the ring gear of the flywheel At the same time a large amount of driving current flows to rotate the motor which transmits the rotational movement to the crankshaft With the Bendix type turning the key switch to the START position causes a small amount of current to flow to
94. ssembly This is not necessary on the FE350 and 400 1 Rocker Arm Pivot 2 Lock Nut 3 Pushrod e Loosen the cylinder head retaining bolts little by little evenly in the reverse order of tightening to remove the cylinder head CAUTION The cylinder head could become warped if the head bolts are not loosened evenly x To ensure the proper loosening sequence refer to the tightening sequence on the next page A E ring B Rocker Shaft C Rocker Arm D Washer FE304751 FE304851 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 27 Cylinder Head Cleaning and Inspection e Inspect the cylinder head for the presence of any cracks or missing fins Replace the cylinder head if any of those conditions exist e Clean the carbon deposits off the combustion chamber and the exhaust port and wash the cylinder head in a cleaning solvent e Place a straightedge against the combustion chamber side of the cylinder head and use a gap gauge to inspect for warpage x If the warpage exceeds the service limit replace the cylinder head Cylinder Head Warpage maximum Service Limit 0 05 mm 0 002 in e Inspect the breather valve Refer to the breather section in Lubrication System A Straightedge B Gap Gauge Reassembly CAUTION Make sure that the piston is in the top dead center of the compression stroke FESO50S1 e Clean the mating surfaces of the cylinder and the cyl
95. t the end of the camshaft A Groove at end of camshaft B Oil Pump Tab FE314451 FE314581 FE314682 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 63 Camshaft A Matching Marks Camshaft Axial Play Adjustment If a part that affects the axial play has been replaced the axial play must be adjusted as described below Shim adjustment is not available on the FE120 and 170 e Place a gasket on the crankcase and measure and record the distance from the gasket surface to the crankshaft gear surface measurement A A Measurement A B Measurement B C Crankcase Cover D Crankcase E Gasket d ee E 222777 a SHE OLA N FE314951 e Measure and record the distance from the crankcase cover mating surface to the end face of the crankshaft bearing inner race mea surement B e Apply these measurements on the crankshaft shim selection table and trace the respective line e Select the next thinner shim that appears on the shim selection table X For example on the FE290 if measurement A is 14 62 mm and measurement B is 16 24 mm the correct shim thickness is t 1 38 mm NOTE O The FE290D camshaft has no shim adjustment 3 64 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Camshaft FE250D Camshaft Shim Selection Table e CUO EN E E E E EU Sr Tele E SAA Se Se EA A A WR R CN R E E E TRT TTT ES RW R R G a R R RR R N R RR EEE o ER
96. tents In these illustrations you will find the instructions indicating which parts require specified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents Before ServiciNg WEE 1 2 EE EEN e ITT 1 4 Periodic Maintenance Gart ici a AA teed A Dai eee 1 6 Special TOONS saat ut as sd ned EE 1 7 Exploded Vis Wii at A A dd 1 8 1 2 GENERAL INFORMATION Before Servicing Before starting to service the engine carefully read the applicable section to eliminate unnecessary work Photographs diagrams notes cautions warnings and detailed descriptions have been included wherever necessary Nevertheless even a detailed account has limitations a certain amount of basic knowledge is required for successful work Especially note the following 1 Dirt Before removal and disassembly clean the engine Any dirt entering the engine carburetor or other parts will work as an abrasive and shorten the life of engine For the same reason before installing a new part clean off any dust or metal filings 2 Battery Ground Remove the ground lead from the battery before performing any disassembly operations on the equipment This prevents a the possibility of accidentally turning the engine over while partially disassembled b sparks at electrical connections which will occur when they are disconnected c damage to electrical parts 3 Tighteni
97. ter the governor gear assembly has been installed e To install first place the thrust washer over the shaft Then install the governor gear assembly with the sleeve attached on the shaft so that step E is fitted securely in groove F e After installing the assembly gently turn the governor by hand to make sure that the governor weight and the sleeve move smoothly A Sleeve B Governor Gear Assemblly C Thrust Washer D Shaft E Step F Groove Governor Arm Installation Setting the Governor e Install the throttle linkage and the spring on the governor arm e Install the governor arm on the governor shaft and hand tighten the clamp nut e Loosen the clamp nut and turn the end of the governor arm all the way in the direction indicated below to keep the throttle valve fully open Meanwhile insert the pin into the hole at the end of the governor shaft turn the end of the governor shaft all the way in the direction indicated below and tighten the clamp nut Direction of Rotation for Tightening the Governor Arm and the Governor Shaft FE120 170 Clockwise FE250 290 350 400 Counterclockwise Governor Shaft Pin Idling Posirion Clockwise Clip End Hole Governor Arm Calmp Nut G JO W E LA M FES01151 FE120 FE170 FE301252 P DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 9 Governor Mechanism A Governor Arm FE250 FE290 FE350 FE400 B Throttle
98. the piston and connecting rod assembly e Remove the snap ring from the piston pull out the piston pin and take out the piston e Using your fingers open the piston ring A at the area where its ends meet and push up the piston ring at the opposite end to remove it from above the piston FE308151 Reassembly The reassembly is the opposite of the assembly e Reassemble the piston rings in the following sequence lower rail A1 spacer B upper rail A2 second ring C top ring D NOTE O Install the top ring and the second ring so that their marked side faces the top of the piston e Beware of the proper direction of the piston when reassembling the piston with the connecting rod NOTE FE308251 O Apply engine oil to the piston pin holes of the piston and the connecting rod before assembling them 3 38 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Piston and Connecting Rod For FE120 170 250 350 400 e On type D face the R mark on the top of the piston towards the side of the connecting rod marked MADE IN JAPAN e On type G face the L mark on the top of the piston towards the side of the connecting rod marked MADE IN JAPAN A Piston B Connecting Rod Type D Type G FE308382 Type D Type G FE308482 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 39 Piston and Connecting Rod For FE290 e On type D face the arrow on the top of
99. the counterclockwise direction This completes the pilot screw adjustment Pilot Screw Throttle Lever Idle Adjustment Screw Low Speed Set Screw Hight Speed Set Screw Governor Arm Pivot Arm Governor Spring Governor Arm Pivot Arm Snap Pin xe E G nm GOW t Incorrect Incorrect Correct FE3004S1 FE300582 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 5 Carburetor Minimum No Load Speed Adjustment e After completing the pilot screw adjustment the minimum no load adjustment must be adjusted e Keep the throttle lever on the carburetor pushed gently to the fully closed position and turn the idle adjustment screw so that the engine runs at 100 rpm lower than the set idle speed This is called the carburetor s idle speed setting e Release the throttle lever of the carburetor to free the speed adjustment lever Turn the low speed set screw on the control panel to set the engine speed to the minimum no load speed Minimum No Load Speed idling Setting crankshaft speed FE120 170 1600 rpm FE250 290 350 400 1300 rpm NOTE O If the minimum no load speed is specified for a particular piece of equipment follow that specification Maximum No Load Speed Adjustment e After completing the minimum no load speed it is necessary to adjust the maximum no load speed e Keep the speed adjustment lever to the high speed side and turn the high speed set screw on the
100. the service limit replace the valve guide with a new one FES06681 A Bore Micrometer Valve Inspection e Inspect the valve head for the presence of any abnormal deposits or gas leakage e Use a wire brush to remove any deposits from the valve e Inspect the valve for any depression in its contact surface A and whether the thickness of the valve head B is below the service limit Valve Head Thickness Service Limit minimum for both Intake and Exhaust FE120 170 0 5 mm 0 020 in FE250 290 350 400 0 6 mm 0 024 in xk If the valve head is smaller than the service limit given above replace FESOG7S1 the valve with a new one 4 Inspect the valve stem for the presence of any gummy deposits discoloration due to seizure or corrosion NOTE O Gummy deposits are caused by the use of old deteriorated gasoline Instruct the user to use fresh unleaded gasoline 3 34 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Valve System xk Use a wire brush to remove the deposits from the valve stem If the valve stem does not move smoothly in the valve guide or the stem shows abnormal wear replace the valve with a new one e Using a micrometer measure the valve stem diameter in several places Xx If the measured value is smaller than the service limit replace the valve with a new one Valve Stem Diameter Service Limit minimum Intake Valve Exhaust Valve FE120 170 5 430 mm 0 2138 in 5 415
101. the text thoroughly familiarize yourself with the procedures before starting work and then do the work carefully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may adversely affect safe operation To get the longest life out of your engine e Follow the Periodic Maintenance Chart in the Service Manual e Be alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki engine parts Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual carefully Don t take shortcuts e Remember to keep complete records of maintenance and repair with dates and any new parts installed How to Use This Manual In preparing this manual we divided the product into its major systems These systems became the manual s chapters All information for a particular system from adjustment through disassembly and inspection is located in a single chapter The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Table of Contents The Periodic Maintenance Chart is located in the General Information chapter The chart gives a time schedule for required maintenance operations If you want spark plug information for
102. tment 12 mm 0 in clearance on cold engine unnecessary Spark Plug Electrode Gap 0 7 0 8 mm 0 028 0 031 in Ignition Coil Air Gap Standard 0 3 mm 0 012 in Adjustment range 0 25 0 4 mm 0 010 0 016 in SERVICE DATA 2 9 Tightening Torque Specifications Tightening Torque Specifications Unit N m kg m ft lb Tightening Torque Tightening Location FE350 FE120 FE170 FE250 FE290 FE400 Cylinder Head Bolts 25 2 5 18 Connecting Rod Bolts 12 20 23 Apply Oil to Threadss before Tightening 1 2 8 9 in Ib 2 0 15 2 3 17 Flywheel Retaning Nut 64 86 137 thoroughly degrease tapered area 6 5 47 8 8 63 14 0 101 9 8 Crankcase Cover 1 0 7 2 2 2 Rocker Arm Lock Nut Valve Clearance Adjustment Lock Nut ziert Muffler Flange Nut 0 7 61 in Ib 1 0 7 2 22 16 9 8 1 0 7 2 8 8 0 9 78in lb 20 2 0 15 Fan Retaining or Fan Presser Plate Electric Starter Retaining Bolt 15 1 5 11 9 8 1 0 7 2 20 2 0 15 Oil Drain Plug Spark Plug 32 3 3 24 23 2 3 17 Fuel Tank 9 8 1 0 7 2 Retaining Bolts for Fan Housing Shroud Recoil Starter 5 9 0 6 52 in Ib General Bolts and Nuts M8 15 1 5 11 5 9 0 6 52 in Ib 3 4 0 35 30 in Ib Oil Level Sensor Bracket M6 Tapping Screws 1 2 0 12 11 in lb 9 8 1 0 7 2 3 4 9 8 Starter Motor Battery Terminal Nut 0 35 30
103. ug is contaminated with oil wash it in a cleaning solvent e If the electrode is worn or the insulator is cracked replace the spark plug e Using a gap gauge measure the electrode gap of the spark plug If the gap is incorrect adjust it to the correct gap by bending the horizontal electrode Spark Plug Electrode Gap Standard 0 7 0 8 mm 0 030 0 032 in e Tighten the spark plug to the specified torque Ignition Plug Specification Tightening Torque 23 N m 2 3 kg m 17 ft lb A Center Electrode B Horizontal Electrode C Insulator D Electrode Gap Betore Top LT TTT TT TTT TTT Titre Dead Center 1111111111111 Ignition timing Crank shaft speed nien FE301951 FES02081 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 15 Ignition System Ignition Coil Inspection Spark Characteristics Measurement e Connect the ignition coil to a coil tester to measure its spark characteristics Follow the measurement instructions provided by the tester manufacturer for the proper measurement procedure For testing purposes remove the plug cap from the ignition coil Ignition Coil Spark Characteristics three wire spark gap Standard 7 mm 0 28 in minimum If the spark characteristics are below the standard the ignition coil is defective If the spark characteristics are normal the plug cap is defective Ignitio
104. ulated by the pilot air jet and the resulting mixture is supplied via the pilot port and bypass port to the engine The fuel that is used during idling is supplied primarily via the pilot port Pilot Jet Pilot Air Jet Body Jet Pilot Port Bypass Port Pilot Screw Pilot Port nmoou gt Main system The function of this system is to supply fuel during medium to high speed high load operating conditions Fuel is regulated by the main jet and flows through the main nozzle The air that is regulated by the main air jet intermixes with the fuel via the bleed hole of the main nozzle and is discharged into the venturi in an emulsion form in which the liquid is intermixed with air bubbles In the venturi the airflow from the air cleaner causes the fuel to become atomized and the resulting air fuel mixture is fed into the cylinder Choke System Closing the choke valve decreases the volume of air intake and increases the intake vacuum during the intake stroke As a result a greater volume of fuel than normal is discharged from the pilot and main systems to facilitate the starting of a cold engine Float System The function of the float is to maintain the fuel in the float chamber of the carburetor at a constant level so that the proper amount of fuel can be supplied to the engine Setting the fuel level in the float chamber to low makes it more difficult for the carburetor to draw the fuel up to the venturi resultin
105. ulty Switch or high tension lead faulty Air gap between ignition coil and magnet incorrect Flywheel demagnetized e Pulsar coil faulty if equipped with CDI igniter Replace Replace Correct Replace Replace Yes Is compression sufficient Choke the carburetor crank the engine a few times remove the spark plug and check its electrode Is it wet Add Clean No fuel in the tank Fuel pipe or filter plugged with dust or air Air hole in tank cap plugged Fuel line in carburetor plugged Clean Clean e Choke used excessively Air cleaner plugged Fuel level in float bowl too hiah Open Clean Replace gt Check for plugged fuel line e Check for plugged air passage e Check fuel level in float bowl Check carburetor setting Check the carburetor Replace Clean or replac Bore or replace Retighten Lap Lap Piston piston rings worn e Piston rings stuck e Cylinder bore worn Cylinder head bolts insufficiently tightened e Valve seat faulty contact Plunge up by valve e Cylinder head warped Valve spring broken e Valve stuck e Cylinder head gasket burned Correct Replace Replace Clean or grind Replace Await proper operation time e Plunge up of HLA device on FE350 or FE400 SERVICE DATA 2 13 Troubleshooting Engine hard to start integrated ignition coil and igniter
106. urface Then turn the oil filter by hand an additional 3 4 Edge turn e Pour in the specified amount of engine oil e Start the engine operate it approximately 3 minutes and then stop the engine Inspect around the oil filter to make sure that there is no oil leak e The oil level decreases by an amount that is equivalent to the capacity of the oil filter Replenish the oil to this amount 3 54 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Crankshaft Disassembly e Remove the crankcase cover e If axial play adjustment shims are provided for the crankshaft and the camshaft remove the shims and identify them so that they can be installed correctly during reassembly e Place the cylinder block on a base so that the flywheel side faces down Keep the tappet or the HLA on FE350 or 400 pushed up towards the cylinder head e After aligning the matching marks on the crankshaft gear and the camshaft gear take out the camshaft e Remove the tappet or the HLA on FE350 or 400 from the crankcase and place an identification mark on it so that the tappet can be reinstalled in its original position X After taking out the HLA of the FE350 or 400 keep the side in which the snap ring is visible upright If it is placed on its side or upside down the oil that is sealed in the HLA unit could leak out disabling the HLA function e On the FE250 290 350 or 400 engine remove the retaining nuts H from the balancer guide G
107. ve Correct Is the compression sufficient e Refer to section on Engine hard to start Fuel consumption excessive Yes Is the compression sufficient Carburetor improperly adjusted Adjust Air cleaner plugged Clean e Idle speed excessive Adjust e Choke valve not fully open Open e Refer to section on Engine hard to start SERVICE DATA 2 15 Troubleshooting Engine runs poorly Fuel system problem insufficient fuel Clean Remove Clean Clean Correct e Dust or water in fuel line or fuel filter e Fuel line plugged with air or vapor lock Fuel tank cap air hole plugged e Air in carburetor and fuel line plugged Carburetor pilot air screw insufficiently opened Governor system problem Engine speed ES Governor linkage improperly fitted Correct gt Governor spring faulty Replace e Governor gear related parts malfunction Replace Clean Correct Replace or correct Retighten or replace Replace Clean Adjust e Fuel line plugged Carburetor improperly adjusted e Spark plug fouled or gap improperly adjusted gt Carburetor flange gasket leaking e Carburetor throttle valve worn e Tank cap air hole plugged e Governor malfunction Engine knocking ES Engine knocking Ignition timing improper Replace igniter separate type Replace ignition integrated type e Fuel quality poor Replace e Combustion cham
108. vement mass such as the piston piston pin piston ring and the small end of the connecting rod On the FE400 350 290 and 250 a reciprocal movement balancer system in which balance weight is linked to the crankshaft has been adopted This is the most effective method for canceling the inertia that is generated by the reciprocal movement mass thus reducing vibration Crankshaft Link Rod Spacer Crankcase Balance Weight O ring Balancer Guide Nut TOnTmMUOOU gt FE313082 X The FE170 can be provided with a uniaxial rotation balancer as a factory option A Crankshaft B Balancer Drive Gear C Balancer Shaft D Balancer Gear FE313182 3 58 DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE Balancer Reciprocal Movement Balancer FE400 350 290 250 Disassembly e Remove the retaining nuts from the balancer guide and pull out the balancer guide from the crankcase e Remove the connecting rod bolt and remove the connecting rod cap e Turn the crankshaft to be near the top dead center to push the connecting rod up Then turn the crankshaft 90 counterclockwise as viewed from the PTO side Remove the crankshaft together with the balancer from the crankcase through an area in which it does not interfere with the connecting rod NOTE O Be careful not to damage the oil seal when removing the crankshaft e Remove the balancer link rod from the crankshaft NOTE O The balanc
109. wear or scratches could be caused by the presence of foreign particles in the engine oil X Vertical scratches or discoloration on the bearing surface is a symptom that results from insufficient lubrication or overheating X Clean the inside of the engine and change the engine oil Inspect and clean the cooling system xk Inspect the oil pump oil filter and oil passage and repair or replace as needed When reusing the connecting rod or the crankshaft carefully file off any protrusions from their bearing surface e Using an inside micrometer measure the bore of the bearing area of the small end in several places Connecting Rod Small End Bearing Area Bore Service Limit maximum FE120 14 042 mm 0 5528 in FE170 16 047 mm 0 6318 in FE250 18 051 mm 0 7107 in FE290 19 051 mm 0 7500 in FE350 400 20 051 mm 0 7894 in x If the measured value is greater than the service limit replace the connecting rod with a new one FES09281 e Mate the connecting rod cap to the big end of the connecting rod and tighten the connecting rod bolts to the specified torque Make sure to apply engine oil to the threaded portion of the connecting rod bolts before tightening them Refer to the section on Tightening Torque Specifications e Using an inside micrometer measure the bore of the bearing area of the big end in several places Connecting Rod Big End Bearing Area Bore Service Limit maximum FE120 26 052 mm 1 0257 in
110. wiring diagrams are common to all models the standard equipment FE202EWS 2 12 SERVICE DATA Troubleshooting If the engine malfunctions first check whether th engine has been operated correctly Then systematically carry out the troubleshooting procedure starting with simple items This troubleshooting chart lists typical malfunctions Do not unnecessarily disassemble any parts before the cause of the problem is identified Engine hard to start separate ignition coil and igniter No Yes Remove a spark plug touch it against the engine block and crank Are sparks produced when the spark plug is replaced Spark plug faulty Replace the engine to check for sparks Because gasoline in the form of atomized air fuel mixture is discharged through the spark plug hole in the engine at this time place the spark plug as far away as possible from the spark plug hole while making contact Are sparks produced between the tip of the high tension lead with the spark plug cap removed and the engine block while the engine is being cranked Are sparks produced between the high tension lead and the engine block when the igniter is replaced WARNING To prevent electrical shock do not hold the spark plug itself Make sure to hold the plug cap d Yes e Contact faulty between Correct plug cap and high tension lead Igniter faulty Replace e Ignition coil fa
111. witch Red exciter Red pulser Grey ground ignition Black switch 10 10 10 10 Red exciter 10 Light Green 10 Red pulser Grey ground 1k 10k 200 k 2 k 10 10 pm 10 2 10 co 10 co 10 co ane ignition DISASSEMBLY REASSEMBLY INSPECTION AND MAINTENANCE 3 17 Ignition System Controller with Warning Light Measurement e Set the measurement range of the hand tester to R x 1 kQ and measure the resistance at the areas given in the table below Controller without ground Resistance KO Tester Negative Tester Positive Terminal Terminal C black D black yellow C black D black yellow FE14ES1 Tester Negative Terminal C black D black yellow E brown If the measured value differs from the table above replace the controller Xx To inspect the oil warning light LED refer to the section on the lubrication system A Igniter FET BEST B Oil Warning Light C Primary Terminal D Oil Level Sensor Terminal E Ground Terminal Flywheel Disassembly and Reassembly e Using a strap wrench hold the flywheel and remove the flywheel retaining nut e Use a flywheel puller to remove the flywheel A Strap Wrench NOTE If an appropriate flywheel puller is unavailable position the flywheel nut flush with the crankshaft end and strike it with a mallet to remove the flywheel

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