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1. KFO4000BW5 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 4 LUBRICATION SYSTEM Specifications So a rr Engine Oil Type Viscosity Capacity Level Oil Pressure Oil Filter By pass Valve Openning Pressure SF SG SH or SJ class SAE40 SAE30 SAE10W 30 SAE10W 40 or SAE5W 20 When filter is not removed 1 5 L 1 6 US qt When filter is removed 1 7 L 1 8 US qt Operating range grid area on dipstick 241 to 310 kPa 35 to 45 psi 3000 rom 78 5 117 5 kPa 11 4 17 1 psi AA ae ee A A Oil Pump Inner and outer rotor clearance Outer rotor outside diameter Outer rotor thickness Pump housing inside diameter Pump housing depth Pump shaft outside diameter Pump shaft bearing inside diameter Relief valve spring free length 0 2 mm 0 008 in 40 470 mm 1 5933 in 9 830 mm 0 3870 in 40 801 mm 1 6063 in 10 230 mm 0 4028 in 10 923 mm 0 4300 in 11 072 mm 0 4359 in 19 50 mm 0 77 in Special Tool Oil Filter Wrench 57001 1249 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LUBRICATION SYSTEM 6 5 Engine Oil and Oil Filter CAUTION Engine operation with insufficient deteriorated or contami nated engine oil will cause accelerated wear and may result in engine seizure and accident Before starting the engine for the first time add oil The engine is shipped
2. Check for loose or lost nuts and screws Check battery electrolyte level Clean air cleaner foam element 1 Clean air cleaner paper element Tighten nuts and screws Change engine oil Clean and re gap spark plugs Change Oil filter Change air cleaner paper element 1 x Check and adjust valve clearance x Clean and lap valve seating surface o P9 P11 Clean combustion chamber o P7 1 Service more frequently under dusty conditions x These items must be performed with the proper tools See your authorized Kawasaki Engine Dealer for service unless you have the proper equipment and mechanical proficiency www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 3 Specifications Item Standard Fuel System Idle speed 1 Low idle speed High idle speed Air cleaner Type Pre cleaner Second stage cleaner Engine Top End Valve clearance Intake Exhaust Valve seating surface angle Intake Exhaust Valve seating surface width Intake Exhaust Lubrication System Engine oil Type Viscosity Capacity Level Electrical System Spark plug gap 1550 r min rpm 3600 r min rpm Dual stage filtration system Foam element Paper element 0 10 0 15 mm 0 004 0 006 in 45 0 6 0 9 mm 0 024 0 035 in SF SG SH or SJ class SAE40 SAE30 SAE10W 30 10W 40 or SAE5W 20 When filter is not removed
3. Venturi diameter 14 mm 0 55 in 16 mm 0 63 in Main Jet MJ 78 88 Pilot jet PJ 40 Pilot air screw turns out PS 11 4 1 5 8 Idle mixture screw turns out Float level Float parallel to carburetor body Idle Speed 1 Low idle speed 1550 r min rpm High idle speed 3600 r min rpm Air Cleaner Type Dual stage filtration system Pre cleaner Foam element Second stage cleaner Paper element Fuel Fuel requirement Unleaded regular grade gasoline Fuel Pump Type Pulse diaphragm pump Governor Type Flyweight all speed governor 1 Idle speeds may vary depending on each equipment Refer to the equipment specification www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 5 Governor Link Mechanism Control Panel Assembly Removal e Remove Air Cleaner see Cleaner Body Removal Control Panel Mounting Bolts A e Remove the control panel assembly A while unhooking the governor spring B end loop at the panel bracket e Clear the choke link rod lower end C from the choke lever 430VP302 P Control Panel Assembly Installation e Before installing the control panel assembly check to see that the choke lever A and engine speed control lever B move smoothly in all directions x If any part is worn or damaged replace the control panel assembly e After installation adjust the low idle speeds and high idle speeds to the specifications see Peri
4. 1 5 L 1 6 US at When filter is removed 1 7 L 1 8 US at When engine is completely dry 1 8 L 1 9 US at Operating range grid area on dipstick 0 75 mm 0 030 in 1 Idle speeds may vary depending on each equipment Refer to the equipment specification Special Tools Valve Seat Cutter 45 627 5 57001 1114 Valve Seat Cutter 32 625 0 57001 1118 Valve Seat Cutter 32 428 0 57001 1119 Valve Seat Cutter Holder Bar 57001 1128 Valve Seat Cutter Holder 46 0 57001 1360 Oil Filter Wrench 57001 1249 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 4 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Low Idle Speed Adjustment e Disconnect all possilble external loads from the engine e Start the engine and warm it up thoroughly WA TO Always keep your hands clear of the moving parts e Move the throttle lever on dash to the idle position and hold the throttle lever on the carburetor in closed position turn the governor arm clockwise all the way and adjust the low idle speed screw A until the engine idles at specified speed Idle Speed Carburetor idle rpm 1450 rpm e Release the throttle lever and adjust the low idle speed set screw B on the control plate to obtain the specified governed low idle speed Low Idle Speed Governed idle rpm 1550 rpm High Idle Speed Adjustment NOTE O High id
5. x If the measurement is less than the service limit replace the spring Valve Spring Free Length Service Limit 31 5 mm 1 24 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 12 ENGINE TOP END Cylinder Piston Piston Removal e Split the crankcase see Camshaft Crankshaft chapter e Remove the camshaft see Camshaft Crankshaft chapter e Turn the crankshaft to expose the connecting rod cap bolts A e Remove the bolts and take off the connecting rod caps B NOTE Note the position of the connecting rod caps for reinstalling the caps e Push the connecting rod end into the cylinder and pull the piston and connecting rod out of the cylinder CAUTION Note the location of the arrow match mark A on the piston head in relation to K Mark B on the connecting rod No 1 cyl K Mark on the connecting rod is face to face with No 2 cyl K Mark on the connecting rod Keep parts together as a set e Remove one of the piston pin snap rings A with needle nose pliers B e Remove the piston by pushing the piston pin A out the side from which the snap ring was removed e Remove the top and second rings with piston ring pliers Special Tool Piston Ring Pliers 57001 115 e l the special tool is not available carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it
6. 65 48 mm 2 577 2 578 in Final Bore Diameter Oversize Final Bore Diameter 0 50 mm 65 48 65 50 mm 2 578 2 579 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 18 ENGINE TOP END Cylinder Piston Change to a honing stone for finishing the final bore diameter should be as shown in the table Be sure the correct stone is used and the stone is not worn e Clean the cylinder at the top and bottom of the cylinder to remove burns and pieces of the base and head gasket e Anchor the cylinder block on the drill press table before honing e Align the center of the cylinder bore to the press center Set the press to operate from 200 to 250 rpm e Connect the drive shaft to the hone and set the stop on the drill press so the hone can only extend 20 to 25 mm 3 4 to 1 0 in above the top or below the bottom of the cylinder liner e Rotate the adjusting nut knob on the hone until the stones contact snugly against the cylinder wall at the narrowest point Do not Force e Turn the stone by hand If you cannot turn it the stone is too tight Loosen the hone until it can be turned by hand e Be sure that the cylinder and hone are centered and aligned with the drive shaft and drill spindle e Pour honing oil inside of the cylinder during the honing operation Start the drill press Move the hone up and down in the cylinder approximately 20 cycles per minute e Ch
7. Ball Plate G Governor Assembly Installation e Fit the snap rings A into the grooves securely e Spin the governor plate by hand and check that the steel balls and governor plate operate freely www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 7 Governor Link Mechanism Governor Assembly Inspection O Visually check all governor parts for wear and damage If any parts are worn or damaged replace them Governor Shaft Removal e Split the crankcase see Camshaft Crankcase chapter e Unscrew the governor shaft plate screws A and pull out the governor shaft B outside NOTE O It is not necessary to remove the governor shaft unless it is being replaced e Replace the oil seal only if the lip shows signs of leakage or it has been damaged e The oil seal A must be assembled with seal lip towards inside of the engine e Press in the oil seal 0 1 0 mm 0 04 in B flush or below the crankcase surface C Governor Shaft Installation e Apply engine oil to the governor shaft e Insert the governor shaft into the crankcase e Install the governor shaft plate A to the shaft B as shown Torque Governor Shaft Plate Screws 2 0 N m 0 20 kgf m 18 in Ib e Check that the governor shaft moves freely in its operating range NOTE O If the oil seal is removed oil seal is put on after shaft is installed www mymowerpart
8. Hand Tester 57001 1394 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Charts ais 2 2 Specifications tr ia io Eco 2 3 Periodic Maintenance Procedures iii aaa 2 4 ESA A O 2 4 Cow ldle Speed Adjustment ainia deeded aan alletanenc ad reins 2 4 High dle Speed Adjustinentisc fcc hers poke a th geri de nein tape niohradi shi oe daale atl aE Saia 2 4 Fuel system Cleanliness InSpeCtions linia at oe nut Alia 2 5 Fuel Pump Inspection ica aetna nthe AA ee ee 2 5 Fuel Filter Inspection cera o ae ae ete eee 2 5 Air Element iRemoval c 8ciacaulienidadiiah blak des 2 6 Air Element Installation s o tocata index Aa hae ea ceed aeaa aba neaparat esap aaa 2 6 Air Element Cleaning and INSpection c ceecesscceseeseeeseeseaeeeseeeseecaeeeaeeeseesaeeseaeesaeecseesaeseaeesaeeseaeseaeeeaeessaeseaeseaeeniees 2 6 Air Cleaner Housing Case and Body INSP CtiON ceeccecececeeeeeeeeeneeteeeeeeeeeaeesaeeseeteaeeeeeeeeeeseeeeeaeeseesneeeeaeeeeesenretes 2 7 Engine TOP ENC nord alan tio 2 7 Cylinder Head Cleaning and Inspection oococnccnnonicncniccnnncnonnconnnnnnnnnnnnnnc canon rnn crac narco nn 2 7 Valve Clearance IiSpection etica aa N ELA area DEIA 2 8 Valve Clearance Adj stMeNt srest iadi a a a a
9. e Fasten the harness A into the clamps B on the intake manifold C Position the harness on top of the manifold as shown e Install the other removed parts Kc10001BS1 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 15 Intake Manifold Intake Manifold Inspection e Inspect the intake manifold for cracks e Cracks not visible to the eye may be detected by using a metal crack detection system Visual color check commonly found at automotive parts store If a crack is present in the intake manifold replace it e Inspect the gasket surfaces for burrs and nicks www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 16 FUEL SYSTEM Fuel Pump Fuel Filter The fuel pump cannot be disassembled if any damage to the pump is noticed replace it with a new one Fuel Pump Inspection O Refer to Fuel Pump Inspection in the Periodic Maintenance Chapter 2nd chapter Fuel Filter Inspection O Refer to Fuel Filter Inspection in the Periodic Maintenance Chapter 2nd chapter www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 17 Air Cleaner Element Removal O Refer to Air Element Removal in the Periodic Maintenance Chapter 2nd chapter Element Installation O Refer to Air Element Instalation in the Periodic Maintenance Chapter 2nd chapter Element Cleaning and
10. CHAMPION RCJ8Y Float type fixed main jet Fuel pump Diaphragm type pulse pump Air cleaner Dual stage element dry type Governor Lubrication system Oil filter Oil capacity when engine is completely dr Cooling system Dimensions LxWxH Electric starter model Recoil starter model Flyweight all speed governor Pressure feed by positive displacement pump Cartridge type full flow filter 1 8 L 1 9 US qt Forced air cooling by fan 421 mm x 350 mm x 325 mm 16 6 in x 13 8 in x 12 8 in 421 mm x 350 mm x 353 mm 16 6 in x 13 8 in x 13 9 in Dry weight Electric starter model Recoil starter model 31 8 kg 70 1 lb 29 8 kg 65 7 lb Specifications subject to change without notice www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 1 6 GENERAL INFORMATION Torque and Locking Agent The following tables list the tightening torque for the major fasteners and the parts requiring use of a non permanent locking agent or liquid gasket Letters used in the Remarks column mean L Apply a non permanent locking agent to the threads M Apply a molybdenum disulfide lubricant grease or oil to the threads seated surface or washer O Apply an oil to the threads seated surface or washer S Tighten the fasteners following the specified sequence SS Apply silicone sealant Fuel System Throttle Valve Screws 0 7 0 07 6 in lb Main Jet 2 3
11. and measure warp by inserting a thickness gauge B between the straightedge and head x If warp exceeds the service limit repair the mating surface Replace the cylinder head if the mating surface is badly damaged Cylinder Head Warp Service Limit 0 03 mm 0 001 in KE04002BS1 C e Check the cylinder head for cracks or other damage e Cracks not visible to the eye may be detached by using a metal crack detection system Visual color check commonly found at automotive parts tore e f a crack is present in the cylinder head replace it e Inspect the mating surface for burrs and nicks www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 8 PERIODIC MAINTENANCE Periodic Maintenance Procedures Valve Clearance Inspection NOTE O Valve clearance must be checked when the engine is cold at room temperature e Remove the rocker cover see Engine Top End chapter e Place the piston at top dead center TDC of the compression stroke turning the crankshaft clockwise facing the flywheel No 1 Cylinder O The left projection A on the flywheel is faced with the right leg B on the 1 ignition coil C as shown epale O Check the intake and exhaust valves are closed completely if not turn the flywheel one turn 360 clockwise and face the left projection with the right leg again No 2 Cylinder O The left projection A on the flywheel is faced with the right leg
12. e Replace the pilot screw in accordance with the following procedure if necessary O Carefully mark the position of the pilot screw limiter on the carburetor body so that it can be installed and set to its original position later O Remove the limiter Be careful not to turn pilot screw at this point Turn the pilot screw clockwise and count the number of turns until screw is gently seated in the pilot passage Record the number of turns needed to closed the screw Turn out the pilot screw to replace it with a new one O Install the new pilot screw until the screw is gently seated Then open the screw the same number of turns as recorded prior to removal O Align the limiter with the mark on the carburetor body to install taking care not to turn the pilot screw e Install the choke valve and throttle valve on the shaft as the out side mark of them facing out side e Drive the float pin into the carburetor body from the choke valve side e Assemble carburetor parts with recommended tightening torque see Exploded View Limiter Pilot Screw Spring Washer O Ring Low Idle Speed Screw Spring E Screws Throttle Valve Throttle Shaft Dust Seal KCO5006BS3 E E O MN Choke Valve Choke Shaft Dust Seal Bolt Gasket Float Chamber Gasket Float Pin Float Main Jet Nozzle Assembly Float Valve P Pp PO PO HH a ds ON ODANDALKW www mymowe
13. oil Level e The oil level should be the operating range D grid area on the dipstick If the oil level is ADD range E add enough engine oil to bring oil level to the operating range CAUTION Do not add more oil above the operating range Excess oil will cause a smoking condition O Use the same type and make of oil that is already in the engine NOTE O If the engine oil type and make are unknown use any brand of the specified oil to top up the level in preference to running the engine with the oil level low Then at your earliest convenience change the oil completely x If the oil level is FULL range F drain the excess oil by loosening the drain plug www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Oil Change e Change the oil after first 8 hours of operation Thereafter change oil every 100 hours e Start and warm up the engine so the oil will drain easily Stop the engine e Place the engine on a level surface e Place a suitable container under the engine e Remove the drain plug A and drain the oil AWARNING Be careful of hot oil when drained burn you severely It may be hot enough to e Check the O ring B at the drain plug for damage Replace the O ring with a new one if it is damaged e Install the drain plug with the O ring and tighten it Tor
14. C 0 60 kgf m 52 in lb T3 7 8 N m 0 80 kgf m 69 in lb T4 15 N m 1 5 kgf m 11 ft lb T1 3 4 N m 0 35 kgf m 30 in lb T5 56 N m 5 7 kgf m 41 ft lb T2 5 9 N m www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 COOLING SYSTEM 4 3 Cooling Fan Cooling Fan Removal O Refer to Flywheel Removal in Electrical System Chapter Cooling Fan Installation O Refer to Flywheel Installation in Electrical System Chapter Cooling Fan Inspection e Visually inspect the blades A in the cooling fan B x If they are any cracks warps or damage replace the cooling fan x If any mud or dust have stuck to the cooling fan clean it e Cooling fan is cleaned by washing in detergent and water CAUTION Do not clean the cooling fan in oil solvent It may be damage by oil solvent www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 1 Engine Top End Table of Contents Exploded VOW tits cde hacen tt deeds 5 2 Specifications A Sanaa et AA ae Re SGT Rod 5 4 Gylinder Head ccoo sl pais Ali 5 5 Compression Measurement csvacntat app ida ida qe dd tad 5 5 Cylinder Head Assembly Remov l ennir caneiro i E EE A E 5 6 Cylinder Head Assembly Installation rnoun noga E 5 6 Push Rod Removal lia e ene a ee 5 7 A
15. Inspection O Refer to Air Element Cleaning and Inspection in the Periodic Mainte nance Chapter 2nd chapter Cleaner Body Removal e Remove the elements see Periodic Maintenance chapter e Remove the cleaner body mounting bolts A and holder plate nuts B e Pull the breather tube A off the pipe at the back of the body and remove the cleaner body B 430VP315 P Cleaner Body Installation e Connect the breather tube from the crankcase to the pipe at the back of the cleaner body e Tighten the holder plate nuts and cleaner body mounting bolts Torque Holder Plate Nuts 5 9 N m 0 60 kg m 52 in Ib Cleaner Body Mounting Bolts 5 9 N m 0 60 kg m 52 in Ib Housing Case and Body Inspection O Refer to Air Cleaner Housing Case and Body Inspection in the Periodic Maintenance Chapter 2nd chaper www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 COOLING SYSTEM 4 1 Cooling System Table of Contents Exploded MW e A iaa tl aa 4 2 Cooling Em td A 4 3 Gooling Fan Removal cuicos pe hele en ee 4 3 Cooling Fan Installation it either elit kal accom ahaa ie dei eee aia 4 3 Cooling Fan INSPEChOM sia ic iaa td eed ated ie es et 4 3 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 2 COOLING SYSTEM Exploded View KDO2000BW4
16. Starter B Recoil Starter Installation e Install the recoil starter and tighten the mounting nuts Torque Recoil Starter Mounting Nuts 5 9 N m 0 60 kgf m 52 in Ib Recoil Starter Disassembly e Remove the recoil starter see Recoil Starter Removal e Pull the handle A out 30 cm 1 ft and clamp the rope B with the clip C so it can not wind back onto the reel D e Pry the knot E out of the handle and untie it e Remove the handle from the rope AWARNING Wear gloves to avoid injury for the remaining steps e While carefully holding the reel A and case B remove the clip e Unwind the spring tension slowly NOTE Do not wedge the rope between the reel and case www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 8 21 Starter System e Remove Screw A Washer B Retainer C Center Spring D Washer E Pawls F Return Springs G AWARNING When removing the reel A be careful that the recoil spring B under the reel does not fly loose and cause injury The spring is under great pressure NOTE O There should be no spring tension on the reel when removing it If tension is felt push the reel back into place and gently wiggle it until the reel can be easily removed e Slowly lift the reel straight up out of the case C AWARNING If the recoil spring cas
17. System chapter Muffler see Muffler Exhaust Pipe Removal Intake Manifold see Fuel System chapter Spark Plug e Unscrew the rocker cover mounting bolts A and remove the cover B and gasket e When removing the 1 2 cylinder head set each cylinder at T D C A of power stroke in e Loosen the cylinder head bolts 1 4 turn in the sequence shown CAUTION If the above procedure is not followed the cylinder head may be warped during removal e Repeat the sequence until all bolts are removed and lift off the cylinder head assembly NOTE Mark the push rods so they can be installed in their original position during assembly Cylinder Head Assembly Installation e Clean the mating surfaces of the cylinder heads and cylinder e Install the push rods in their original positions on each cylinder see Push Rod Installation e Install the knock pins e Set each cylinder at T D C A of power stroke in e Put new gaskets and the cylinder head assemblies on each cylinder then align the push rods under the rocker arms NOTE O Because the head gaskets are coated with sealing agents be careful not to damage the surfaces KEO4000BS1 C e Tighten the cylinder head bolts following the tightening sequence Torque Cylinder Head Bolts 25 N m 2 6 kgf m 19 ft lb 1 CYLINDER 2 CYLINDER CAUTION A torque wrench must be used to assure proper torque Improper tightening of the head bolts can r
18. and no more Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the notch B in the edge of the piston pin hole CAUTION Do not reuse the snap rings as removal weakens and deforms them They could fall out and score the cylinder wall www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 14 ENGINE TOP END Cylinder Piston e Apply engine oil to the piston skirt and the cylinder bore x Using the piston ring compressor grip A and the belt B lightly tap the top of the piston with a plastic mallet C to insert the piston and connecting rod into the cylinder Special Tools Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 57001 1096 e Insert the piston and connecting rod so that the arrow mark A on the top of the piston is facing the flywheel side B CAUTION The connecting rod and the connecting rod big end cap are machined at the factory in the assembled state so they must be replaced together as a set e Apply engine oil to the inner surface A of the connecting rod big end B and caps C e Install the connecting rod big end caps in their original position on each connecting rod big ends e Apply a small amount of engine oil to the thread D and seating surface E of the cap bolts e Tighten the cap bolts Torque Connecting Rod Big End Cap Bolts 5 9
19. angle to the direction of the piston pin hole x If the measurement is less than the service limit replace the piston Piston Diameter Service Limit 64 79 mm 2 551 in KEO6001BS1 C Cylinder Inside Diameter e Clean and measure the cylinder inside diameter O Use a dial bore gauge to measure front to back and side to side at the points shown figure If any of the cylinder bore measurements is greater than the service limit the cylinder must be bored to the next oversize and then honed see Cylinder Boring and Honing Cylinder Inside Diameter standard Service Limit Standard Cylinder 64 98 65 00 mm 65 10 mm 2 558 2 559 in 2 563 in 0 5 mm Oversize 65 48 65 50 mm 65 60 mm Cylinder 2 578 2 579 in 2 583 in Cylinder Bore Out of Round Standard 0 01 mm 0 004 in Service Limit 0 056 mm 0 0022 in Cylinder Boring and Honing Always resize to exactly 0 5 mm 0 02 in over the standard bore size If this is done accurately the stock oversize rings and piston will fit perfectly and proper clearance will be maintained Resizing the cylinder bore can be done by reliable repair shop or by using a drill press and honing tool Use the stone recommended by the hone manufacturer to produce correct cylinder wall finish Machine bore first the bore diameters should be shown in the table Final Boring Bore Diameter Oversize Final Boring Bore Diameter 0 50 mm 65 46
20. are defined as follows Standards show dimensions or performances which brand new parts or systems have Service Limits indicate the usable limits If the measurement shows excessive wear or deteriorated performance replace the damaged parts www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 1 4 GENERAL INFORMATION Model Identification Electric Starter Model Recoil Starter Model FH430V02 P Cylinder Number Designation No 1 Cylinder is the left hand cylinder viewed from the air cleaner No 2 Cylinder is the right hand cylinder viewed from the air cleaner www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 5 General Specifications Type of engine Cylinder layout Bore x Stroke Piston displacement FH381V FH430V Forced air cooled vertical shaft OHV 4 stroke gasoline engine 90 V Twin 65 mm x 65 mm 2 56 in x 2 56 in 431 mL 26 3 cu in Direction of rotation Counterclockwise facing the PTO shaft Compression release Automatic compression release Low idle speed 1550 rpm Fast idle speed 3600 rpm Ignition system Transistorized fly wheel magneto RFI Per Canada and U S A requirements Starting system Electric starter and or recoil starter Charging system 12 V 15 amps with regulator Spark plug Carburetor
21. cleaner see Fuel System chapter e Place a suitable container A under the float chamber mounting bolt B on the carburetor e Remove the float chamber to drain the carburetor and check to see if water or dirt has accumulated in the carburetor e Tighten the float chamber mounting bolt Torque Float Chamber Mounting Bolt 4 5 N m 0 46 kgf m 40 in Ib e l any water or dirt is found clean the carburetor see Fuel System chapter and fuel tank and check the fuel filter Fuel Pump Inspection e Check the vent hole A and filter B for plugging or clogging x If vent hole and filter are plugged or clogged remove the foreign matter from them 430VP204 P Fuel Flow Test AWARNING Gasoline is extremely flammable and can be explosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Disconnect the fuel pump outlet nozzle from the tube e Connect a suitable hose A to the outlet nozzle e Run the lower end of the hose into a container e Start the engine Check the fuel flow x If fuel flow is none or little replace the fuel pump x Check for clogged or damaged tubes and fuel fillter Replace the faulty parts Fuel Filter Inspection e Visually insect the fuel filter A x If the filter is clear with no signs of dirt or other contaminat
22. dry Preoil the engine to force all air from the internal oil passages and the oil filter e Fill fresh engine oil to the specified level see Periodic Maintenance chapter e Run the engine at slow speed 2 minutes e Stop the engine and check the oil level Oil Level Inspection O Refer to Oil Level Inspection in the Periodic Maintenance Chapter 2nd chapter Oil Change O Refer to Oil Change in the Periodic Maintenance Chapter 2nd chapter Oil Filter Change O Refer to Oil Filter Change in the Periodic Maintenance Chapter 2nd chapter www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 6 LUBRICATION SYSTEM Pressurized Lubrication System The engine lubrication circuit is a pressurized system consisting of a positive displacement pump which picks up oil through a filter screen from the crankcase The oil is pumped to a replaceable oil filter cartridge through the engine s oil passages to lubricate internal components and return to the crankcase A pressure relief valve is used between the oil pump and oil filter to relieve excessive oil pressure by returning excess oil to the crankcase see Oil Flow Chart Oil Pressure Measurement e Remove the oil passage plug from the crankcase e Install the oil pressure gauge adapter A and oil pressure gauge B e Run the engine and allow warm up completely e Run the engine at fast idle speed and read the oil pressure gauge e Stop the eng
23. e Do not use unnecessary force on the exhaust pipes when removing the muffler assembly or they could become damaged or distored Muffler Exhaust Pipe Installation e Clean the exhaust pipe flanges and the exhaust port gasket surfaces and install a new gaskets each time the muffler installed e Install the gasket e To prevent mis threading finger tight the flange nuts first Next tighten the hook nut e Tighten the nuts Torque Exhaust Pipe Flange Nuts 15 N m 1 5 kgf m 11 ft lb e Install the muffler e After installation thoroughly warm up the engine wait until the engine cools down and retighten the bolts and nuts Inspection e Inspect the exhaust pipe or muffler for dents cracks rust and holes If the exhaust pipe or muffler is damaged it should be replaced for best performance and least noise e Check the muffler for distortion and or loose internal components Loss of power could develop if loose internal muffler components restrict exhaust flow e Check for breaks in the seams and check weld at the junction of the exhaust pipes and muffler e Tap the muffler with a plastic hammer to decarbonize www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LUBRICATION SYSTEM 6 1 Lubrication System Table of Contents Exploded Mi Wii A eee es 6 2 Engine Oil Flow Cha italia diana
24. e Measure the commutator outside diameter A at several points x If the diameter is less than the service limit replace the armature with a new one Commutator Outside Diameter Service Limit 29 5 mm 1 161 in e Support the armature in an alignment jig at each end of the shaft as shown Position a dial indicator perpendicular to the commutator e Rotate the armature slowly and read the commutator runout x If runout is more than the service limit turn down the commutator or replace the armature with a new one Commutator Runout Service Limit 0 0178 mm 0 0007 in e Test the armature winding for shorts O Place the armature on a growler A O Hold a thin metal strip e g hack saw blade on top of the armature O Turn on the growler and rotate the armature one complete turn x If the metal strip vibrates the windings are internally shorted to each other and the starter motor must be replaced Tall GP110610S1 C GP110607S1 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 20 ELECTRICAL SYSTEM Starter System Pinion Clutch Inspection e Turn the pinion gear by hand The pinion gear should turn clockwise freely x If the pinion clutch does not operate as it should or if it makes noise replace the pinion clutch 430VP815 P Recoil Starter Removal e Remove Recoil Starter Mounting Nuts A Recoil
25. eii io 6 3 Specifications Tiras a aed Alar ee te lee lee ial 6 4 Engine Oil and Oil Filter ee Re eee ad A ee E coo 6 5 Oil Level Inspection sia alta aden ahaa as 6 5 Olli CHANGE ici A tide a ene eee 6 5 Oil Bilter Change tura dd tele dd eee do ols ie 6 5 Pressurized Lubrication System iii a le 6 6 Oil Pressure Measurement s 22 0 28 00st eee id ye ieee 6 6 Oil Pump Relief Valiye esnaera ai cthap eee hese iar eul gick ated aa E a eS 6 7 Oil Pump Relief Valve Removal 2 2 0 cvccsce ciescocessccesscevi excuse evs siuyecccuevsuaes sstccevedescectavegeeveevde as 6 7 Oil Pump Relief Valve Installation ccccscceccscceesseeeseceeeeeeeceeaeeeseaeeeseeeeccsaeeseacecseaeeeseeeessaeeessaeessiaeeeseaeessneeeesieeeees 6 7 Oil Pump Relief Valve INS pectin sinesi nsee eraa r nr 6 7 Oil Sereen tte 6 9 Qil Sere n REMOVAL 22 242 dra tallada 6 9 Oil Screen Installati n niiin a e e ne ee ei eh ee da 6 9 Gleaning and Inspections taaan lt pirado 6 9 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 2 LUBRICATION SYSTEM Exploded View KFO2000BW4 C T1 3 9 N m 0 40 kgf m 35 in lb T2 5 9 N m 0 60 kgf m 52 in Ib T3 6 9 N m 0 70 kgf m 61 in lb T4 See the text O Apply engine oil www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LUBRICATION SYSTEM 6 3 Specifications lin K Zim
26. ignition occurs The placement of the trigger sensor internal to the ignition insures constant timing over speed and temperature and prevents counterclockwise operation The diode D1 in the ignition shut off circuit blocks inadvertent application of battery voltage protecting the internal components of the ignition With the stop switch SW in the closed position primary voltage is routed to ground preventing ignition operation www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 8 15 Charging Ignition System Ignition Coil Removal e Remove Fan Housing see Flywheel Stator Coil Removal Spark Plug Cap A Stop Switch Lead Connector B Bolts C Ignition Coil D Ignition Coil Installation e Install ignition coil on crankcase so that the stop switch lead connector B face the screen and tighten bolt 1 first then tighten bolt 2 While tightening bolts adjust the air gap A between the three legs of ignition coil and the two pole plates of magnet to the specified gap value as shown Ignition Coil Air Gap Standard 0 2 0 4 mm 0 008 0 016 in Torque Ignition Coil Bolts Stud Bolt 7 8 N m 0 80 kgf m 69 in Ib Ignition Coil Bolts Flanged Bolt 5 9 N m 0 60 kgf m 52 in Ib NOTE O Above procedure must be used to insure proper coil air gap is not too large KHO7003BS1 C KHO7004BS1 C www mymowerparts com
27. liter s For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LIST OF ABBREVIATIONS pound s meter s minute s newton s pascal s horsepower pound s per square inch revolution revolution s per minute top dead center total indicator reading volt s watt s ohm s Read OWNER S MANUAL before operating www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emission 1 and exhaust emission 2 control systems EM in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board 1 Crankcase Emission Control System A sealed type crankcase emission control system is used to eliminate blow by gases The blow by gases are led to the breather chamber through the crankcase Then it is led to the air cleaner Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase and then returned back to the bottom of crankcase 2 Exhaust Emission Control System The exhaust emission control system applied to this engine consists of a carburetor and an ignition system having optimum ignition timing characteristics The carburetor has been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exh
28. motor Faulty engine STARTER ROTATES BUT CAN NOT CRANK ENGINE Does pinion mesh with NO gt Worn pinion or ring gear ring gear lncorrect starter alignment Faulty pinion clutch Faulty engine YES Replace STARTER DOES NOT STOP IN ENGINE SWITCH OFF Can stop starter by engine NO gt OFaulty engine switch switch OFF Faulty solenoid switch YES Ls Faulty pinion or ring gear Incorrect starter alignment Faulty pinion return mechanism NO Weak battery Charge or replace Charge or replace Repair or replace Replace Repair or replace Replace Charge or replace Repair or replace Replace Repair or replace Repair or replace Replace Repair or replace Repair or replace Replace Correct Repair or replace Repair or replace Replace Repair or replace Correct Repair or replace www mymowerparts com
29. paa reia ade deri ced aniiatinsederaees 2 8 Valve Seat Inspections i i AA i eee i a 2 9 Valve Seat Repali iia teal ee ida 2 9 Lubrication SyStemixs feteteti ag a ieeliael el deel vide ane el eat ele ti ee ieee ats 2 11 Oil evel Inspection ctrl aia 2 11 Oil CHANGE a ir e sein ata 2 12 Oil Filter GnanQ y taiwan tats deh is ioe iatined ad dena ida A ine eri aia eae 2 12 Gil Filter Installation tanda rt le tad 2 12 Electrical SV SM iaa A dd de 2 13 Spark Plug Cleaning and INSpectiON ooooniccccnnninnnnnccnnncnncnncncn nn conc ronca cnn 2 13 Spark Plud Gap Inspection ds 2 13 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 2 PERIODIC MAINTENANCE Periodic Maintenance Chart To ensure satisfactory operation over an extended period of time any engine requires normal maintenance regular intervals The Periodic Maintenance Chart below shows periodic inspection and maintenance items and suitable intervals The bullet mark designates that the corresponding item should be performed at that interval Some adjustments require the use of special tools or other equipment An electronic tachometer will facilitate setting idle and running speeds OPERATION INTERVAL Daily First Every Every Every Every Every Refer 8 hr 25 hr 50 hr 100 hr 200 hr 300 hr ence Check or clean air intake screen o Check and add engine oil o P11 Check for fuel and oil leakage
30. service limit replace the valve A Valve Head Thickness Service Limit IN EX 0 35 mm 0 014 in e a a COo Valve Stem Runout e Support the valve in V blocks at each end of the stem e Position a dial gauge perpendicular to the stem e Turn the valve and read the variation on the dial gauge x If the stem runout is greater than service limit replace the valve Valve Stem Runout Service Limit IN EX 0 05 mm 0 002 in GE030107S1 C Valve Stem Diameter e Measure the diameter of the valve stem A in two directions at right angles at four different positions on the stem x If any single measurement is less than the service limit replace the valve Valve Stem Diameter Service Limit Intake 5 95 mm 0 234 in Exhaust 5 93 mm 0 233 in Valve Guide Inside Diameter e Use a small bore gauge or a micrometer to measure the inside diameter A of the valve guide B at three places down the length of the guide x If the measurement is more than the service limit replace the cylinder head with a new one Valve Guide Inside Diameter Service Limit Intake Exhaust 6 08 mm 0 239 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 11 Valves Valve Spring Inspection e Inspect the valve spring for pitting cracks rusting and burns Replace the spring if necessary e Measure the free length A of the spring
31. 0 006 mm 0 0002 in full indicator reading e Finish the crankpin surface with a super finishing stone www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 8 1 Electrical System Table of Contents Exploded Mi Wii A le ell a Ae ie 8 2 SPCCHICATONS O cetaceans selec sevens 8 4 Wiring Diagram ei 2c 05 sitet ete et dei a ae davies Ages d 8 5 PrecCautlonS incisive he ne Ba el oe ese i i ete an ee ne GR 8 8 Ghargings IgnitiOn SYSteMs ciedad dd des et 8 9 Flywheel Stator Coil Removal siise dan daa i n 8 9 Flywheel Stator Coil Installation cc ccccscccssscceeeceeceeceeceneeeeceeessaeeeceaeeesaeeseeaeesceaeescaesecaeeeseeesseaeeseeaeeseneeesiaeeess 8 10 Charging System Operational INSPOCtION ccceeceeete eens eeeeeeeeeeeeeeeaeeceeeeaeeeaeesaeeeeeseaeesiaeeeeeeaeesaeeeeeeseeeeeaeeseeetsaeeeas 8 11 Stator Goll Resistance nearne eiieeii iain ieee Mina ade ea etn ha 8 12 Unregulated StatoriOutputcra niet cal oe ee ee dena edie Rabie Scola 8 12 Regulator Removal viii A oe ee ee 8 12 Regulator Installation lt 25 cst scadascchnadecussch cade ccbesczedtastaaiges easehospacecs agers shaeaden oda sdainessiad fsteshdsaueas ETT 8 12 Regulator Resistance coccion ini a ai 8 13 Ignition Goil Removal timida 8 15 IgnitionGoll InstallatiON 0 dans tonne ain nwa awaited hia heli i aA
32. 0 23 20 in lb Float Chamber Mounting Bolt 4 5 0 46 40 in lb Carburetor Governor Arm Clamp Nut 7 8 0 80 69 in lb Governor Shaft Plate Screws 2 0 0 20 18 in lb Holder Plate Nuts Air Cleaner 5 9 0 60 52 in lb Carburetor Mounting Intake Manifold Mounting Bolts 6 9 0 70 61 in lb S Cleaner Body Mounting Bolts 5 9 0 60 52 in lb Control Panel Mounting Bolts 5 9 0 60 52 in lb Cooling System Engine shroud Bolt M8 15 1 5 11 Engine shroud Bolts M6 5 9 0 60 52 in lb Engine shroud Bolts Studs 7 8 0 80 69 in lb Plug Screw Engine shroud 3 4 0 35 30 in lb Flywheel Bolt 56 5 7 41 Engine Top End Cylinder Head Bolts x25 2 6 19 S Valve Clearance Lock Screws 6 9 0 70 61 in lb Connecting Rod Big End 5 9 0 60 x52 in lb x 0 Cap Bolts Rocker Arm Bolts 28 2 8 20 Rocker Cover Mounting Bolts 5 9 0 60 52 in lb Exhaust Pipe Flange Nuts 15 15 11 Spark Plugs 22 2 2 16 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 7 Torque and Locking Agent Fastener Torque Remarks Lubrication System Engine Drain Plugs 61 in lb Oil Passage Plug 35 in lb Oil Pump Cover Plate Mounting Bolts 52 in lb Oil Filter in the text Camshaft Crankshaft Crankcase Cover Bolts 25 i 19 0 x S Breather Chamber Cover Bolts E E 52 in lb Electrical System Starter Coil Screws Flywheel Bolt Fan Housing Bolts Screen Screws Regulator Screws Ignition Coil Bolts Studs Ignition Coil B
33. 0 kgf m 52 in Ib T3 7 8 N m 0 80 kgf m 69 in Ib T4 15 N m 1 5 kgf m 11 ft lb G Apply grease O Apply engine oil www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 4 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Charging System Regulated output voltage Alternator stator coil resistance Unregulated stator output Regulator resistance 14 1 V DC 3600 rpm in the text 28 4 V AC 3000 rpm in the text 15 V DC 3600 rpm 26V AC 3000 rpm Ignition System Ignition coil Primary winding resistance Secondary winding resistance Spark Plug Plug gap in the text 8 to 11 KQ CHAMPION RCJ8Y 0 75 mm 0 030 in Electric Starter System Starter motor Carbon brush length with spring boss Commutator groove depth approx Commutator diameter Commutator runout Special Tool Hand Tester 57001 1394 12 0 mm 0 500 in 2 0 mm 0 078 in 31 5 mm 1 240 in 4 0 mm 0 157 in 1 0 mm 0 039 in 29 5 mm 1 161 in 0 0178 mm 0 007 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 8 5 Wiring Diagram Note Portion surrounded by shows KHI procurement parts iy Spark Plugs Starter H Pr Carburetor Voltage J Regulator rv RERS Charging Bex A aa E wY Coi H E a TP o j A os E ZA i y Option T 0il Pressure Switc
34. 0 rpm x l the AC voltage reading is less than the specification replace the stator Unregulated Stator Output MIN 26 VAC 3 000 rpm Regulator Removal e Remove Stator Coil Lead Connector A Regulator Screws B Regulator C 430VP809 P Regulator Installation e Install the regulator and tighten the screws Torque Regulator Screws 3 4 N m 0 35 kgf m 30 in Ib www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 8 13 Charging Ignition System Regulator Resistance e Set the KAWASAKI Hand Tester selector switch to the R x 100 2 position e Connect the test leads to the points shown on the chart and read the resistance There are two 2 types of Regulator on FH engines as follows O O with out Charging Monitor Type 3 Blades O A Resistance value may vary with individual meters With Charging Monitor type 5 Blades ug Be DONES E mo T5KQ 925 Q 925 O 1OKQ 10KQ co 00 12KQ co 110 Q 00 x If the resistance is not as specified replace the regulator www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 14 ELECTRICAL SYSTEM Charging Ignition System This engine ignition is controlled by a solid state ignition assembly and requires no periodic maintenance except for the spark plugs The system consists of the following Induc
35. 01 115 Piston Ring Compression Grip 57001 1095 Piston Ring Compression Belt 455 67 57001 1096 Valve Seat Cutter Holder Bar 57001 1128 Valve Seat Cutter Holder 6 57001 1360 Valve Seat Cutter 45 627 5 57001 1114 Valve Seat Cutter 32 628 0 57001 1119 Valve Seat Cutter 32 625 0 57001 1118 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 5 Cylinder Head Compression Measurement e Before measuring compression do the following Be sure the battery is fully charged O Thoroughly warm up the engine so that engine oil between the piston and cylinder wall will help seal compression as it does during normal running O Stop the engine e Disconnect the spark plug caps of each cylinder and remove the spark plugs e Attach the compression gauge assembly firmly into one plug hole Special Tools Compression Gauge 57001 221 A Compression Gauge Adapter 57001 1159 B e Ground the spark plugs to the engine AWARNING To avoid fire do not ground the spark plugs in proximity to the plug holes Keep the plugs as far away as possible from the plug holes e With the throttle fully open turn engine over with the recoil starter several times until the compression gauge stops rising the compres sion is the highest reading obtainable Recoil Starter Model Cylinder Compression MIN 390 kPa 57 psi e Using the starter motor turn
36. Ait GIO AMON ccc toe cece ata e lid oia 3 17 Element Removal ai monien onenean eraa eea aa asra daa a e aenar ca 3 17 Element InstallatiON 00 aa io lis 3 17 Element Cleaning and InspectiON somotirian ida ratio anand ari 3 17 Cleaner Body Removal recnici no a it di i 3 17 Cleaner Body Installation str cdi aa 3 17 Housing Case and Body INSpectiON oooooncccnncnnnnicnccnoncnnccnnnnnnancconcconn nro 3 17 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 2 FUEL SYSTEM Exploded View i e RY aX DA WN Y KC02002BW4 C 1 Pilot Screw T1 0 7 N m 0 07 kgf m 6 in Ib 2 Main Jet T2 2 3 N m 0 23 kgf m 20 in lb T3 4 5 N m 0 46 kgf m 40 in Ib T4 5 9 N m 0 60 kgf m 52 in lb T5 6 9 N m 0 70 kgf m 61 in Ib L Apply non permanent locking agent O Apply engine oil S Follow the specific tightening sequence www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 3 Exploded View KC02003BW4 C T1 2 0 N m 0 20 kgf m 18 in Ib T2 5 9 N m 0 60 kgf m 52 in lb T3 7 8 N m 0 80 kgf m 69 in Ib O Apply engine oil www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 4 FUEL SYSTEM Specifications Standard FH381V FH430V Caburetors Specifications Make type Walbro LMF 2 Walbro LMF 1 Throttle bore diameter 24 mm 0 94 in
37. B on the 2 ignition coil C as shown Follow No 1 Cylinder alignment KEO5001BS1 C e Then check the valve clearance Using a thickness gauge A measure the valve clearance beween the rocker arm B and the valve stem end x If the valve clearance is incorrect adjust it Valve Clearance when cold Intake Exhaust 0 10 0 15 mm 0 004 0 006in Valve Clearance Adjustment e Since valve repairs change the valve clearance adjust the valve clearance to the specification e Assemble the cylinder head and install the cylinder head assembly on the block see Engine Top End chapter e Turn the crankshaft to the proper direction until the piston is at TDC of the compression stroke described above e Loosen the lock screws A and valve clearance adjusting nuts B e Insert a 0 10 mm 0 004 in thickness gauge C between the rocker arm and valve stem and tighten the adjusting nut until the thickness gauge begins to bind between the rocker arm and valve stem end Use a sweeping motion with the thickness gauge while making this adjustment Valve Clearance when cold Intake Exhaust 0 10 0 15 mm 0 004 0 006in e Holding the adjusting nut with a wrench tighten the lock screw to the specified torque Torque Valve Clearance Lock Screws 6 9 N m 0 70 kgf m 61 in Ib e Do not overtighten e Remeasure any clearance that was adjusted Readjust if necessary www mymowerparts co
38. Cutter Operating Cares 1 This valve seat cutter is designed only for valve seat repair Therefore the cutter must not be used for other purposes 2 Do not drop or hit the valve seat cutter or the diamond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE O Do not use a wire brush to remove the metal particles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder A in position operate the cutter B with one hand C Do not apply too much force to the diamond portion NOTE Prior to grinding apply oil to the cutter and during the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash the cutter with washing oil and apply a thin layer of engine oil before storing www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 10 PERIODIC MAINTENANCE Periodic Maintenance Procedures Marks Stamped on the Cutter The marks stamped on the back of the cutter represent the following 1 Cutter number selected from 1 to 12 30 Cutter angle A 37 5 Cutter diameter of cutter B KS8B Manufactured lot number Operating Procedures e Clean the seat area carefully e Recondition the valve seats with the valve seat cutters 45 32 and
39. For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 16 ELECTRICAL SYSTEM Charging Ignition System Ignition Coil Inspection e Remove the ignition coils see Ignition Coil Removal e Measure the winding resistance as follows O Set the hand tester to the R x 1 kQ range Special Tool Hand Tester 57001 1394 O Make the measurements shown in the table Ignition Coil Winding Resistance 2 18kQ 18kQ Cc 2 Use only Tester 57001 1394 with new battery at room tempera ture for this test A tester other than the Kawasaki Hand Tester should show different readings If a megger or a meter with a large capacity battery is used the ignition coil will be damaged CAUTION x If the tester does not read as specified replace the coil Spark Plug Removal e Carefully pull the plug cap from the spark plug e Remove the spark plugs using a suitable plug wrench Spark Plug Installation e Insert the spark plug vertically into the plug hole with the plug installed in the plug wrench e Tighten the plugs Torque Spark Plugs 22 N m 2 2 kgf m 16 ft lb e Fit the plug caps securely e Pull up the spark plug caps lightly to make sure of the installation of the spark plug caps Spark Plug Cleaning and Inspection O Refer to Spark Plug Cleaning and Inspection in the Periodic Mainte nance Chapter 2nd chapter Spark Plug Gap Inspection O Refer to Spark Plug Gap Inspection in the Periodic Main
40. For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FH381V FH430V Kawasaki 4 stroke air cooled v twin gasoline engine Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Department Consumer Products amp Machinery Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts 2001 Kawasaki Heavy Industries Ltd First Edition 1 Oct 1 2001 K www mymowerparts com ampere s after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree s Celsius direct current farad s degree s Fahrenheit foot feet gram s hour s
41. HOOTING 9 5 Engine Troubleshooting Guide Fuel consumption is excessive Is compression sufficient Oil consumption is excessive Is compression sufficient Engine backfires Are gt NO High fuel level in carb float chamber including overflow High idling R P M Choke partially closed Excessively backed off carbu retor pilot screw Worn piston piston rings Stuck piston Worn cylinder bore lnsufficient cyl head tightness Faulty valve seat contact Plunge up of valve Wrong valve timing Broken valve spring Stuck valve Engine knocks Plugged oil ring groove High oil level Worn valve stems and valve guide 0il leakage along governor shaft Oil leakage from oil seal O0il leakage from mounting surface O0il leakage from drain plug Clogged breather valve Drain back hole in breather chamber plugged lncorrect oil viscosity Worn piston rings Stuck piston rings Worn cylinder bore Broken piston ring Loose carb or intake manifold Loose cyl head or leaking head gasket Burned or sticking intake valve Faulty ignition coil Carb not properly adjusted Stale fuel Excessive carbon deposit in engine Excessive engine load Engine overheating Faulty ignition coil Adjust Adjust Open choke Adjust Replace Clean or replace Bore or replace Retighten Lap Ad
42. N elo AAEE EAEE ri osito 5 7 Push Rod INSpection 2 msni oead Ea aaa eaa e aaee aala a apaa a dei alan 5 8 Valve Mechanism Removal lnstallation cccceescessseeseneeeeseeeeneeeeeaeeeseaeeeeeaeeeseaeeeeneeeeeneeeeeeeeessaeeeseneeeeeneeesnaeeensaeeeed 5 8 Cleaning and Inspection at ara Gene dd ricas ibi 5 9 Rocker Arm INSPOCtiON siea siais artonde puririn pan naeve e di 5 9 O NO 5 10 Valve Clearance Inspection iia dd 5 10 Valve Clearance AdjUSIMEN iasi eieiei es 5 10 Valve SeatiInspectionizs usario dt pi 5 10 ValVe Se atea nas 5 10 Valve Head THICKNESS Rua e E 5 10 Valve Stem RUNOUts cios ataca ts 5 10 Valve Stem Diet dia 5 10 Valve Guide Inside Diametetis i22 fetch nemesis nih died deeb cinched A an tia and 5 10 Valve Spring Inspection ea ae ie eh A ed eee ee 5 11 Cylinders PISTON ca tees Seber eek cot A A E A uk cases seus E E it sasha seared 5 12 Piston Removal volcan Lei ee at id ee wi E 5 12 Pist n Installation a AAA AAA ee ee ee ees 5 13 Piston Gylinder S iZure acia ico tata ra ata aaa renta 5 14 Piston Civic ai dia hy 5 15 Piston Ring and Ring Groove Wear ococoncnnnnnoninninncninanan senses seesaeeeseeeseenecaeense 5 15 Piston Ring End Gap taxi nadar 5 16 Piston Pin Piston Pin Hole and Connecting Rod Wearl ccccscceceseeeesseceseeeeeseeeeseeessaeeeceaeeeeeaeesseaeeeenseeesnseeeees 5 16 Piston Dia Molestar odie da 5 17 Cylinder Inside Diameter miniin enin ea Adie i veered Medien ev E Er N ae 5 17 Cyl
43. N m 0 60 kgf m 52 in Ib e Install Camshaft see Camshaft Crankshaft chapter Crankcase Cover see Camshaft Crankshaft chapter Piston Cylinder Seizure e In case of seizure remove the piston e Visually inspect the cylinder and piston damage x If there is only light damage smooth the position with 400 emery cloth Remove the small aluminum deposits from the cylinder with 400 emery cloth or light honing x If the damage is severe both cylinders must be bored oversize and oversized pistons installed www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 15 Cylinder Piston Piston Cleaning e Remove the piston and piston rings see Piston Removal CAUTION Never clean the piston head with the engine assembled Carbon particles will fall between the piston and cylinder and damage the crankshaft bearings e Scrape the carbon off A the piston head e Use the scraping tools carefully Do not gouge the piston head To avoid gouging use scrapers that are made of a material that will not cause damage e Clean the piston ring grooves A with a broken piston ring or other suitable tools CAUTION Be careful not to widen the ring grooves Damaged ring grooves will require piston replacement Piston Ring and Ring Groove Wear e Clean the piston see Piston Cleaning e Visually inspect the piston rings and ring grooves x If the
44. Ns de 3 6 Governor Assembly Removal ivi A ad 3 6 Governor Assembly Installati n vecino nn e t 3 6 Governor Assembly Inspection 3a hice a iia 3 7 Governor Shaft Removal miii a aida 3 7 Governor Shaft Installations a a aida 3 7 GarbUretOR tidad a dada 3 8 Fueltand Air FIOW Ansehn AA A At a IE 3 8 Low ldl Sp ed Adjustment ccracsedavned att da tada de dead ones 3 9 High Idle Speed Adjustment sico db 3 9 High Altitude Operation cti ia id 3 9 Main Jet Replacement iii pta 3 9 Fuel system Cleanliness INSPe Ction cccccecceescecseeceeeeeseeeseeceeeeeeeeeaeecaeeeaeecaeeeaeesaeesaeseaeesaeessaeseaeeeaeesaeeseaeenaeeeeetaas 3 9 Carburetor Removal Roiera ee eel tes haces atheist erties eset ated des Rat ee Ee eee 3 10 Carburetor Installation 3 10 Carburetor Disassembly ASSOMD Y cecceecceeeeeeeeeeeceeeeeeeaeesaeecsaeeeaeeeaeesseeseaeenacesaeecsaeeeaeseaeesaeeseaeeeaeessaeseaeeeaeeeeetaas 3 11 Carburetor Clean mcr ete sidan event etree eer ae eth halved ie ad 3 12 Carburetor INSPECTION orador ados ie reis Oz Edad 3 12 Intake Manifoldis sietinas dl dd a lb dad 3 14 Intake Manifold Roma miii r EE vt edd eee 3 14 intake Manifold Installation cico siii pia 3 14 Intake Manifold InSpections ccccccissievhecs ice aclviesineesnte ier eeecd e doo 3 15 Fuel Pump Fuel IBIGD st ce Astras kceenas dst ast ii esla dias 3 16 Fuel Pump ANSpectiOn astucia ina ri aa 3 16 Fuel Filter Inspection iii id aE Geode ee a EAE 3 16
45. Worn piston piston rings Stuck piston rings Worn cyl bore lnsufficient cyl head tightening Faulty contact valve seat Plunge up by valve Warped cyl head Broken valve spring Stuck valve of Burned head gasket Replace Clean or replace t Bore or replace Retighten E Lap H Adjust valve clearance Replace Replace Clean or replace Replace www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING 9 3 Engine Troubleshooting Guide Engine power loss Is engine overheated YES gt Crankcase low on oil Too much oil in crankcase NO i i Excessive engine load Carb not properly adjusted Carbon deposit in combustion chamber O Clogging of cooling system Damaged cooling fan Adjust level or add Adjust level Decrease load Adjust Clean Clean Replace Is the ignition spark NO gt Wrong spark plug Replace normal O Faulty ignition coil Replace YES Incorrect air gap Adjust gap Is lubricating condition NO gt O Too much or too little oil in Correct normal crankcase YES Excessively contaminated lub Change ricating oil O Defective oil filter Replace Faulty relief valve Replace Faulty oil pump Replace Clogging oil system Clean Is unusual smoke emitted YES Plu
46. all 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 13 Periodic Maintenance Procedures Electrical System Spark Plug Cleaning and Inspection e Remove the spark plug See Electrical System chapter x If the plug is oily or has carbon build up on it clean the plug using a high flash point solvent and a wire brush or other suitable tool x If the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug or its equivalent A Insulator B Center Electrode C Plug Gap D Side Electrode Spark Plug Gap Inspection e Measure the gap with a wire type thickness gauge x If the gap is incorrect carefully bend the side electrode with a suitable tool to obtain the correct gap Spark Plug Gap Standard 0 75 mm 0 030 in KX XXX XXX ES al SII il 2AN GP100123S1 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 1 Fuel System Table of Contents Exploded View ssi ain A ee ee 3 2 SPCCHIGATIONS 2 5 fos ES T TE AET 3 4 Governor Link MechanisM casan oo A 3 5 Control Panel Assembly Removal ovio A a RAEE 3 5 Control Panel Assembly Installation a ts 3 5 Governor Arm Removal cerae nri enri AAEE dais 3 5 GovernonArim NStallation citas do cats aea pence a Ut eee ee
47. an be explosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove Air Cleaner and Related Parts see Cleaner Body e Turn the fuel shut off valve to the OFF position e Drain the carburetor e Disconnect the fuel tube at the fuel inlet joint A of the carburetor e Unhook the throttle link spring B at the throttle shaft lever C top end with a long nose pliers e Unhook the throttle D and choke link rods E at the top ends of their arms while pull off the carburetor Carburetor Installation e Clean the mating surfaces of the carburetor and intake manifold and fit the new gaskets e Take care not to bend the throttle and choke link rods during installation Make sure the link spring around the throttle link rod is in place and that it pulls the governor arm and carburetor throttle shaft lever toward each other e Adjust Carburetor Pilot Screw Idle Speed www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 11 Carburetor Carburetor Disassembly Assembly e Refer to the illustration shown for disassembly and assembly e There are several passage plugs Ball plugs in the carburetor body Do not remove e Before disassembly mark the out side of choke valve and throttle valves for assembling them
48. arated from the gases in the breather chamber and then returned back to the crankcase cover gt Fresh Air au Blow by Gas A il To cylinder Head KGO8000BW4 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 7 7 Breather Breather Chamber Cover Removal e Remove the bolts A and breather chamber cover B Breather Chamber Cover Installation e Apply sealant A to the mating surface of the crankcase Sealant Kawasaki Bond Silicone Sealant 56019 120 e Install a new gasket and the breather chamber cover and tighten the bolts Torque Breather Chamber Cover Bolts 5 9 N m 0 60 kgf m 52 in Ib www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 8 CAMSHAFT CRANKSHAFT Camshaft Tappet Camshaft Tappet Removal e Set the engine on a clean surface while parts are being removed e Drain the oil see Lubrication System chapter e Remove Muffler see Engine Top End chapter Throttle Control Panel see Fuel System chapter Carburetor see Fuel System chapter Intake Manifold see Fuel System chapter Crankcase Cover see Crankcase Cover Removal Rocker Covers A 430VP703 P e Position the piston TDC at the end of the compression stroke e Push down A the spring side of the rocker arm B and move it to clear the push rod C e Remove the push rods and mark them so they can be install
49. ate 8 15 Ignition Coil Inspection ina dd olan ee es 8 16 Spark Plug Removalvo ciao iii S E Oil 8 16 Spark Plug Installation eee Den eed ie SE eae eee 8 16 Spark Plug Cleaning and INSpectiON ccoonconcinnninnnonncnnosnrncnnncnnn nn rn cren recen 8 16 Spark Plug Gap Inspection alteran atan dia 8 16 RS NS 8 17 Starter Motor Removal traidos 8 17 Starter Motor Installationie coccion add 8 17 Starter Motor DisaSsoMblVi conc il a lin 8 17 Startet Motor Assembly dorar adan 8 18 Starter Motor Brush Insp ctioN misrin A da 8 18 Brush Spring Inspection it idad a 8 18 Armature InSpectiON iomimconiain ia o E a Rca 8 19 Pinion Clutch IASpEctiON tua a 8 20 RecolliStarter Removal timida cda 8 20 Recoil Starter Installationen A A a DARAN 8 20 Recoil Starter Disassembly siester riesi keeda TR aE E eade dd 8 20 Recoil Starter ASSOMbIY esenea nenea ra 8 22 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 2 ELECTRICAL SYSTEM Exploded View FS SS ee aa E ns ee lt p KHO2000BW4 C T1 3 4 N m 0 35 kgf m 30 in Ib T2 5 9 N m 0 60 kgf m 52 in lb T3 7 8 N m 0 80 kgf m 69 in Ib T4 22 N m 2 2 kgf m 16 ft lb T5 56 N m 5 7 kgf m 41 ft lb www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 8 3 Exploded View KHO2001BW4 C T1 3 9 N m 0 40 kgf m 35 in Ib T2 5 9 N m 0 6
50. aust system TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED Federal law and California State law prohibits the following acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new engine for the purpose of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the engine after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Do not tamper with the original emission related part Carburetor and internal parts Spark plugs Magneto or electronic ignition system Fuel filter element Air cleaner elements Crankcase Cylinder heads Breather chamber and internal parts Intake pipe and tube www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily Whenever the owner has insufficie
51. ble the carburetor Carburetor Inspection AWARNING Gasoline is extremely flammable and can be explosive under certain Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Inspect the carburetor body for damage Flange sealing surfaces should be smooth and free of burrs and nicks Replace the gasket if necessary e Turn the throttle and choke shafts to check that the throttle and choke butterfly valves move smoothly x If the valves do not move smoothly replace the carburetor body and or throttle shaft and choke shaft assembly e Check the gasket on the carburetor body x If the gasket is not in good condition replace it e Check the other parts of the carburetor for wear or damage Replace the part if necessary e Clean and check the float level as follows CAUTION Do not push down on the float during float level checking www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 13 Carburetor e With the float A assembly installed onto the carburetor body B hold the carburetor upside down at eye level Gently support the float with a finger and bring it down slowly so that the float arm tab C just touches the float valve D The float lower surface E should be parallel with the carburetor body mating surfaces F x If the float po
52. d Installation e Install Piston see Engine Top End chapter Crankshaft Removal e Set the engine on a clean surface while parts are being removed e Drain the oil see Lubrication System chapter e Remove Flywheel see Electrical System chapter Camshaft see Camshaft Tappet Removal Connecting Rod and Piston Assembly see Engine Top End chapter e Pull the crankshaft A out of the crankcase Tap gently with a wooden or plastic mallet if necessary to loosen the crankshaft Crankshaft Installation e Clean up the crankshaft and crankcase thoroughly especially at the bearing contact surfaces e Pack some amount of high temperature grease into the oil seal on the crankcase e Apply engine oil to the PTO side journal crank pin and bearing e Apply molybdenum disulfide grease e Carefully insert the crankshaft flywheel end into the main bearing and oil seal in the crankcase Cleaning Inspection e After removing clean the crankshaft and connecting rods with a high flash point solvent and dry them with compressed air e Inspect the teeth of the crankshaft gear for pitting fatigue cracks burrs and evidence of improper tooth contact x Replace the gear if necessary e Inspect the crankshaft and connecting rods especially at the bearing surfaces for wear scratches evidence of improper contact or other damages Replace them if necessary Connecting Rod Bend Twist e Measure connecting rod bend O Select an arbor o
53. down in the guide O Check the valve seating surface A between the valve B and valve seat C e Rocker Arm Installation O Soak the valve clearance adjusting nuts and rocker arm in the engine oil O Install the rocker arm www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 9 Cylinder Head Cleaning and Inspection O Refer to Cylinder Head Cleaning and Inspection in the Periodic Maintenance Chapter 2nd chapter Rocker Arm Inspection e Clean and inspect the rocker arm where it touches the push rod and valve stem x If the contact points A are worn or damaged replace the rocker arm KE04003BS1 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 10 ENGINE TOP END Valves Valve Clearance Inspection O Refer to Valve Clearance Inspection in the Periodic Maintenance Chapter 2nd chapter Valve Clearance Adjustment O Refer to Valve Clearance Adjustment in the Periodic Maintenance Chapter 2nd chapter Valve Seat Inspection O Refer to Valve Seat Inspection in the Periodic Maintenance Chapter 2nd chapter Valve Seat Repair O Refer to Valve Seat Repair in the Periodic Maintenance Chapter 2nd chapter Valve Head Thickness e Remove the valve see Valve Mechanism Removal Installation e Measure the thickness of the valve head x If the valve head thickness valve margin A is less than the
54. e Remove the 3 piece oil ring with your thumbs in the same manner GE160606S1 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 13 Cylinder Piston Piston Installation e Install the expander A in the piston oil ring groove so that the B expander ends B touch together never overlap e Install the upper and lower steel rails There is no UP or Down to the rails They can be installed either way GE160130S1 C e Do not mix up the top and second rings e Install the second ring so that the 0 mark faces up e Install the top ring e The rings should turn freely in the grooves A Piston Head B Top Ring C Second Ring KEO6000BS1 C e Align the piston and rings with the piston ring end gap as shown A Arrow Match Marks B Top ring End Gap Upper Steel Rail End Gap C 30 45 D Second Ring End Gap Lower Steel Rail End Gap e Apply engine oil to the piston pins Assemble the pistons onto the connecting rods as follow No 1 cyl Piston align the arrow mark on the piston head with the raised letters K Mark on the connecting rod No 2 cyl piston align the arrow mark on the piston head opposite K Mark on the connecting rod A No 1 Cyl Piston B No 2 Cyl Piston C Arrow Marks D K Mark E Opposite K Mark e When installing a piston pin snap ring compress it only enough to install it
55. e the piston to push it in to be sure it is square e Measure the gap A between the ends of the ring B with a thickness gauge If the end gap of any ring is greater than the service limit replace the entire set of rings Piston Ring End Gap Service Limit Top 0 75 mm 0 029 in Second 0 75 mm 0 029 in Oil 1 05 mm 0 041 in Piston Pin Piston Pin Hole and Connecting Rod Wear e Remove the piston pin e Measure the diameter of the piston pin with a micrometer at several points x If the outside diameter is less than service limit replace the piston pin Piston Pin Outside Diameter Service Limit 15 96 mm 0 628 in e Measure the inside diameter A of the piston pin hole at several points on both side Use a dial bore gauge x If the inside diameter is more than the service limit replace the piston Piston Pin Hole Inside Diameter Service Limit 16 08 mm 0 633 in e Measure the inside diameter A of the small end of the connecting rod at several points Use a dial bore gauge x If the inside diameter is more than the service limit replace the connecting rod Connecting Rod Small End Inside Diameter Service Limit 16 05 mm 0 632 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 17 Cylinder Piston Piston Diameter e Measure the outside diameter A of the piston 12 5 mm 0 9 in up B from the bottom of the piston at a right
56. eck the diameter of the cylinder bore regularly during honing using an inside micrometer CAUTION Stop the drill press before measuring and remove the hone from the cylinder NOTE The finish should not be smooth but have a 40 to 60 degree crosshatch pattern e Hone the cylinder until it is about 0 007 to 0 009 mm 0 0003 to 0 0004 in large to allow for shrinkage when the cylinder cools NOTE Do not use gasoline kerosene or commercial solvent to clean the cylinder bore These fluids only wash all the oil from the cylinder wall They do not remove the metal particles produced during honing KEO6003BS1 C e Using soap warm water and clean rags clean the cylinder wall A clean white rag should not show soil from the cylinder wall e Dry the cylinder and coat with an engine oil CAUTION The cylinder must be thoroughly cleaned after honing to eliminate all grit www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 19 Muffler Exhaust Pipe Installation Muffler Exhaust Pipe Removal e Loosen the clamp nut A e Remove the bolt B on the muffler bracket and take off the muffler e Unscrew the exhaust pipe flange nuts A and remove the exhaust pipe B with pipe cover C Use a penetrating oil if necessary to break threads loose e Remove the gaskets e Unscrew the hook nut D separate the exhaust pipe and pipe cover
57. ed in their original positions during assembly e Turn the crankcase up side down so that the tappets will fall away from the cam lobes e Pull the camshaft A out of the crankcase e Remove the tappets A and mark them so they can be installed in their original positions during assembly Camshaft Tappet Installation e Apply engine oil to the following Tappet Journal Camshaft Journal Cam Lobe Surface Camshaft Gear e Align the punch marks A on the crankshaft gear and camshaft gear e Install the shim B on the camshaft www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 7 9 Camshaft Tappet Camshaft Disassembly e Remove the governor assembly see Fuel System chapter e Remove Spring A O Do not remove the ACR automatic compression release weight B Camshaft Assembly e Install the governor assembly see Fuel System chapter e After assembling the camshaft check the following items O The governor plate A must move freely O While shaking the camshaft ACR weight B swings smoothly Camshaft Inspection e Check the camshaft gear A for pitting fatigue cracks burrs or an evidence of improper tooth contact x Replace the shaft if necessary e Check the top of the cam lobes B for wear burrs or uneven contact x Replace the shaft if necessary Camshaft Bearing Journal Wear e Measure the height of each cam lobe x If the cam
58. element A in a bath of detergent and water and let the element air dry throughly before installing it e Clean the paper element A by tapping it gently on a flat surface to remove dust If the element is very dirty replace it with a new one CAUTION Do not use compressed air to clean the paper element Do not oil the paper or foam element 430VP208 P Air Cleaner Housing Case and Body Inspection e Clean the housing with detergent and water and dry thoroughly e Check the housing for deformation or other damage The housing must seal well and permit only filtered air to reach the carburetor x If the housing is damaged it must be replaced e Check that no foreign material is obstructing the air passage Engine Top End Cylinder Head Cleaning and Inspection e Scrape the carbon deposits from the head and exhaust port with a suitable tool A e To avoid gouging use scrapers that are made of a material that will not cause damage e Clean the head in a bath of high flash point solvent and dry it with compressed air AWARNING Clean the cylinder head in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the cylinder head A fire or explosion could result e Straight edge A across the mating surface of the head at several different points
59. ervice limit Crankshaft Journal Bearing Inside Diameter Service Limit 35 15 mm 1 384 in Cleaning e Remove Camshaft and Tappets see Camshaft Tappet Removal Crankshaft see Crankshaft Removal e Clean up the crankcase and cover with a high flash point solvent and blow out any foreign particles that may be in the pockets inside of the crankcase with compressed air AWARNING Clean the crankcase and cover in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 6 CAMSHAFT CRANKSHAFT Breather The function of the breather is to create a vacuum in the crankcase which prevents oil from being forced out of the engine through the piston rings oil seals or gaskets A sealed type crankcase emission control system is used to eliminate blow by gases The blow by gases are led to the breather chamber through the crankcase and the camshaft Then it is drawn into the clean side of the air cleaner through the cylinder head and the hose and mixed with the clean air flow and subsequently comes into the combustion chamber through the carburetor and the intake manifold Oil is primarily separated from the gases while passing through the inside of the rocker chamber from the crankcase and secondly sep
60. esult in warping of the cylinder head e Check and adjust the valve clearance e Install the gasket and rocker cover Torque Rocker Cover Mounting Bolts 5 9 N m 0 60 kgf m 52 in Ib e Install the other removed parts www mymowerparts com KEO4001BS1 C For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 7 Cylinder Head Push Rod Removal e Set each cylinder at T D C of power stroke e Remove the rocker covers see Cylinder Head Assembly Removal e Loosen the valve clearance adjusting nuts A e Move the rocker arms B to clear the push rod upper ends e Pull out the push rods NOTE O Mark the push rods so they can be installed in their original position during assembly Push Rod Installation e Set each cylinder at T D C of power stroke e Install the push rods A in their original positions on each cylinder O To Install the push rod in the correct position on the tappet B insert the push rod so end of the push rod is sliding down C along inside wall D of the crankcase and position the push rod end onto the tappet e Check that both intake and exhaust push rods on each cylinder are at lowest position on the cam lobes E if not turn the flywheel clockwise one turn 360 and reset each cylinder at T D C of power stroke in e Be sure the end of the push rods are correctly seated on the tappets e Tighten the valve clearance adjusting nuts e Check and adju
61. eter PTO side 15 985 mm 0 6293 in Flywheel side 15 985 mm 0 6293 in Camshaft bearing inside diameter Crankcase 16 136 mm 0 6352 in Crankcase cover 16 136 mm 0 6352 in Crankshaft Connecting Rod Connecting rod bend 0 15 100 mm 0 006 3 94 in Connecting rod twist 0 15 100 mm Connecting rod big end width Crankpin width 0 006 3 94 in 18 80 mm 0 74 in 39 50 mm 1 56 in Connecting rod big end inside diameter 33 055 mm 1 301 in Crankpin Outside diameter 32 94 mm 1 297 in Crankshaft runout 0 05 mm 0 002 in TIR Crankshaft journal diameter PTO side 34 90 mm 1 374 in Flywheel side 34 94 mm 1 376 in Crankcase PTO shaft bearing inside diameter Crankcase Cover 35 15 mm 1 384 in Crankshaft journal bearing inside diameter Crankcase 35 15 mm 1 384 in Sealant Kawasaki Bond Silicone Sealant 56019 120 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 4 CAMSHAFT CRANKSHAFT Crankcase Crankcase Cover Removal e Set the engine on a clean surface while parts are being removed e Drain the oil see Lubrication System chapter e Remove Exhaust Pipe and Muffler see Engine Top End chapter Control Panel see Fuel System chapter Governor Arm see Fuel System chapter e When inverting the engine is necessary to remove the crankcase cover be sure to remove the air cleaner cover and air filter elements Gasoline may drain from the carburetor and soak
62. ey are disconnected c damage to electrical parts 3 Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them evenly in a staggered sequence This is to avoid distortion of the part and or causing gas or oil leakage Conversely when loosening the bolts nuts or screws first loosen all of them by about a quarter of a turn and then remove them Where there is a tightening sequence indication in this Service Manual the bolts nuts or screws must be tightened in the order and method indicated 4 Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench 5 Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removal of screws held by a locking agent in order to avoid damaging the heads 6 Edges Watch for sharp edges especially during major engine disassembly and assembly Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over 7 High Flash Point Solvent A high flash point solvent
63. f the plate fit into holes B e Put the washer C as shown e Tighten the flywheel bolt D Torque Flywheel Bolt 56 N m 5 7 kgf m 41 ft Ib 430VP807 y www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 8 11 Charging Ignition System e Install the fan housing and tighten the bolts Torque Fan housing Bolts 5 9 N m 0 60 kgf m 52 in Ib e Install Recoil Starter see Recoil Starter Installation e Install Spacer A Screen B O Position three sets C of screen notches around the fan blades e Tighten the screen screws D Torque Screen Screws 5 9 N m 0 60 kgf m 52 in Ib KHO7001BS2 C Charging System Operational Inspection e Check battery condition NOTE O Always check battery condition before condemning other parts of the charging system The battery must be fully charged in order to conduct accurate charging system tests e Warm up the engine to bring the components up to their normal operating temperatures e Measure regulated output voltage at various engine speeds O Connect a voltmeter across the battery terminals The readings should show nearly battery voltage when the engine speed is low and as the engine speed rises the readings should also rise But they must stay within the specified range If the output voltage is much higher than the specification the regulator is defective or the regula
64. f the same diameter as the connecting rod big end and insert the arbor through the connecting rod big end O Select an arbor of the same diameter as the piston pin and at least 100 mm long and insert the arbor through the connecting rod small end O On a surface plate set the big end arbor on V blocks With the connecting rod held vertically use a height gauge to measure the difference in the height of the small end arbor above the surface plate over a 100 mm length to determine the amount of connecting rod bend x If connecting rod bend exceeds the service limit the connecting rod must be replaced Connecting Rod Bend Service Limit 0 15 100 mm 0 006 3 94 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 12 CAMSHAFT CRANKSHAFT Crankshaft Connecting Rod e Measure connection rod twist O With the big end arbor still on the V blocks hold the connection rod horizontally and measure the amount that the small end arbor varies from being parallel with the surface plate over a 100 mm length of the arbor to determine the amount of connecting rod twist If connection rod twist exceeds the service limit the connecting rod must be replaced Connecting Rod Twist Service Limit 0 15 100 mm 0 006 3 94 in Connecting Rod Big End Crankpin Width Wear e Measure the connecting rod big end width A with a micrometer or dial caliper If the measurement is less
65. ged 430VP814 P e Install the brush plate and tighten the through bolts as shown 2 12 A Torque Starter Motor Through Bolt 3 9 N m 0 40 kgf m 35 in Ib KHO9002BS1 C Starter Motor Brush Inspection e Measure the overall length of each brush A x If the brushes are shorter than the service limit replace them Brush Length Service Limit 4 0 mm 0 157 in KHO9003BS1 C Brush Spring Inspection e Inspect the brush springs for pitting cracks rusting and burrs x Replace the spring if necessary e Inspect the springs for weakened conditions and distortion x Replace the springs if necessary x If the brush springs are able to press the brushes firmly into place they may be considered serviceable If they cannot replace them www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 8 19 Starter System Armature Inspection e Inspect the surface of the commutator A If it is scratched or dirty polish it with a piece of very fine emery cloth B and clean out the grooves e Measure the depth of the grooves between the commutator segments lf the grooves are shallower than the specified limit replace the armature with a new one x If the grooves are only dirty clean them carefully Commutator Groove Depth Limit Less than 1 0 mm 0 039 in A Bad B Segment C Good D 1 0 mm 0 039 in limit E Mica
66. gged air cleaner Clean out of muffler Carbon deposit in exhaust hole Clean and muffler Carb not properly adjusted Adjust Too much oil in crankcase Adjust level Worn piston piston rings Replace Worn cylinder bore Is compression is compression sufficient gt See Engine Starts Hard Engine runs erratically ___ Spark plug fouled pitted or Replace or adjust gapped incorrectly Problem in the fuel gt Entry of dust or water into fuel system lack of fuel pipe or fuel filter O Air or vapor lock in fuel line Clean O Plugged air vent of fuel tank Clean cap Plugged air fuel passes in carb Clean O Too little opening of carb pilot Correct screw Carb not properly adjusted Adjust Carb flange leaking at gasket Tighten or replace e Worn carb body and throttle shaft Replace Bore or replace Clean www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 9 4 TROUBLESHOOTING Engine Troubleshooting Guide gt Problem in the governor system Engine malfunctions at high speed Is revolution fluctuation of YES relatively large period produced when a load is applied lncorrect governor linkage Correct adjustment Faulty governor spring Replace Governor ass y malfunctioning Check Clean Clean Plugged air hole in tank cap Entry of dust and air i
67. h me E ili CHD 7 Key Switch 5 Oil Light o MO e N 3 4 e Bie p a Solenoid Switch A Battery P hi a KHO4001BW4 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 6 ELECTRICAL SYSTEM Wiring Diagram Note Portion surrounded by shows KHI procurement parts Spark Plugs Charging Coi To Electric Clutch 12V DC Engine Stop Switch KHO4002BW4 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 8 7 Wiring Diagram Note Portion surrounded by shows KHI procurement parts Spark Plugs Engine Stop Switch KHO4003BW4 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 8 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems Learn and observe all the rules below Do not reverse the battery lead connections This will burn out the diodes in the electrical parts O Always check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical system tests O The electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them To prevent damage to electrical parts do not disconnect t
68. haft slowly to measure the runout The difference between the highest and lowest dial gauge readings TIR is the amount of runout x If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Service Limit 0 05 mm 0 002 in TIR Crankshaft Main Journal Wear e Measure both main journals at several points around the journal circumference x If the journal diameter is less than the service limit replace the crankshaft with a new one PTO Side Crankshaft Journal Diameter A Service Limit 34 90 mm 1 374 in Flywheel Side Crankshaft Journal Diameter B Service Limit 34 94 mm 1 376 in Crankpin Resizing Crankpin can be resized to accept 32 5 mm 1 2795 in dia under A size connecting rod The crankpin should be reground if the crankpin is so much undersized and so much scored that a lapping operation will prove unsatisfactory Regrinding can be done by a reliable repair shop gt e Before sending the crankshaft inspect the crankpin for cracks te x If any cracks no matter how small are found the crankshaft must be rejected E e The final finishing dimensions should be shown in the table Finishing Dimensional Specifications A 32 470 32 457 mm 1 278 1 277 in R 2 0 2 4mm C 39 50 mm MAX 1 555 in MAX D 34 550 32 450 mm 1 281 1 278 in e The crankpin surface should be concentric and parallel to each other within
69. he battery leads or any other electrical connections when the engine switch is on or while the engine is running O Because of the large amount of current never keep the engine switch turned to the start position when the starter motor will not turn over or the current may burn out the starter motor windings O Take care not to short the leads that directly connect the battery positive terminal to the chassis ground O Troubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was brought on by some other item or items they too must be repaired or replaced or the replacement part will soon fail again Make sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc Poor wires and bad connections will affect electrical system operation O Measure coil and winding resistance when the part is cold at room temperature O Electrical Connectors Female Connectors A GP060101S1 C Male Connectors B GP060102S1 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 8 9 Charging Ignition System Flywheel Stator Coil Removal e Remove Recoil Starter see Recoil Starter Removal Nuts A and Guard B Screws C and Screen D Spacer E e Loosen the fan housing bolts A and remove the fan ho
70. height is less than the service limit for either lobe replace the camshaft Cam Lobe Height Service Limit IN 29 131 mm 1 1469 in EX 29 131 mm 1 1469 in e Measure both camshaft journals at several points around the journal circumference If the journal diameter is less than the service limit replace the camshaft PTO Side Camshaft Journal Diameter Service Limit 15 985 mm 0 6293 in Flywheel Side Camshaft Journal Diameter Service Limit 15 985 mm 0 6293 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 10 CAMSHAFT CRANKSHAFT Camshaft Tappet e Measure the inside diameter A of the camshaft bearing on the crankcase at several points This bearing is not replaceable x Replace the crankcase if the inside diameter is more than the service limit Camshaft Bearing Inside Diameter Crankcase Service Limit 16 136 mm 0 6352 in e Measure the inside diameter A of the camshaft bearing on the crankcase cover at several points This bearing is not replaceable x Replace the crankcase cover if the inside diameter is more than the service limit Camshaft Bearing Inside Diameter Crankcase Cover Service Limit 16 136 mm 0 6352 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 7 11 Crankshaft Connecting Rod Connecting Rod Removal e Remove Piston see Engine Top End chapter Connecting Ro
71. inder Boring and Honda a aaa e Eaa Tara Eae e EE EAEE aa 5 17 Muffler Exhaust Pipe Installation cecccceeseeeceeeceeeeeeeeeeeeeenseeeeneneeeneneneauaeneeeeseseeeeseeeeseneesneneneasenesaaeseneaeseneaenseneensees 5 19 Muffler Exhaust Pipe RemMoVal eoicinoiaio dont Artie 5 19 Mu tfler Exhaust Pipe Installationis 23 42 aside iii ketene de adas 5 19 INS pectina iciead al ie ie ee a PA neces 5 19 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 2 ENGINE TOP END Exploded View a Sy SY KEO2000BW4 C T1 5 9 N m 0 60 kgf m 52 in Ib T2 6 9 N m 0 70 kgf m 61 in Ib T3 22 N m 2 2 kgf m 16 ft lb T4 25 N m 2 6 kgf m 19 ft lb T5 28 N m 2 8 kgf m 20 ft lb O Apply engine oil G Apply grease S Follow the specific tightening sequence www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 3 Exploded View T1 15 N m 1 5 kgf m 11 ft lb www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 4 ENGINE TOP END Specifications Cylinder Head Cylinder compression MIN Cylinder head warp Valves Valve head thickness Valve stem runout Valve stem diameter Valve guide inside diameter Valve spring free length Rocker arm push rod rounout Cylinder Piston Piston diameter Piston ring groove clearance Piston ring thickness Piston
72. ine e Remove the oil pressure gauge and adapter e Tighten the oil passage plug Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 Oil Pressure Gauge Adapter PT 1 8 57001 1033 Torque Oil Passage Plug 3 9 N m 0 40 kg m 35 in Ib x If the oil pressure is below the specification inspect the oil pump and relief valve If the oil pump and relief valve are not at fault inspect the rest of the lubrication system Oil Pressure 241 to 310 kPa 35 to 45 psi 3000 rpm www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LUBRICATION SYSTEM 6 7 Oil Pump Relief Valve Oil Pump Relief Valve Removal e Remove the crankcase cover see Camshaft Crankshaft chapter e Unscrew the mounting bolts and remove the oil pump parts assembly pump gear pump cover plate pump shaft pins and rotors e Take off the relief valve spring and ball e Disassemble the pump parts assembly A Pins B Pump Gear C Mounting Bolts D Outer Rotor E Inner Rotor F Pump Shaft G Relief Valve Ball H Spring I Pump Cover Plate J 6 mm dia Hole KFO7000BS1 C Oil Pump Relief Valve Installation e Fill the rotor housing with engine oil for initial lubrication e Install the relief valve ball and spring in position then install the pump parts assembly in the crankcase cover NOTE O When Installing the pump parts assembly align the 6 mm dia hole A on the cover plate with center
73. ing the oil seal A of the governor shaft note the following O Install the oil seal into the crankcase cover B after the governor shaft is inserted in the cover and so that the marks C face out O The depth is 0 1 mm 00 04 in D e When installing the governor shaft and plate in the crankcase cover see Fuel System chapter www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 7 5 Crankcase e Check to see that the crankcase dowel pins A are in place on the crankcase e Install the gasket on the crankcase e Install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence shown Torque Crankcase Cover Bolts 25 N m 2 6 kgf m 19 0 ft Ib Do not turn one bolt down completely before the others as it may cause the crankcase cover to warp GIR NC ONN LLO ONSAS SA y NA Inspection e Measure the inside diameter A of the PTO shaft bearing on the crankcase cover at several points This bearing is not replaceable Replace the crankcase cover if the inside diameter is more than the service limit PTO Shaft Bearing Inside Diameter Service Limit 35 15 mm 1 384 in e Measure the inside diameter A of the crankshaft journal bearing on the crankcase at several points This bearing is not replaceable Replace the crankcase if the inside diameter is more than the s
74. into the filter S elements if the air cleaner case is not removed QUA KG04000BS1 C CAUTION If the carburetor bowl has gasoline in it the gasoline may spill out if the engine is turned upside down Use caution when inverting the engine e Unscrew the mounting bolts A and remove the crankcase cover B from the crankcase O There are two knock pins on the crankcase mating surface A wooden or plastic mallet may be used to gently tap loose the crankcase cover Crankcase Cover Installation e Chip off the old gasket from the mating surfaces of the crankcase and cover e Using compressed air blow out the oil passage in the crankcase cover e With a high flash point solvent clean off the mating surfaces of the crankcase and cover and wipe dry WA TO Clean the crankcase and cover in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean parts A fire or explosion could result e Be sure to replace any oil seal removed with a new one O Install the oil seal so that the marks A face out O Thoroughly pack high temperature grease B into the space between the seal lip C and dust lip D Press in the new oil seal using a press or suitable tools until it is flush with flange surface E Do not damage the seal lips e When replac
75. ion it is OK and need not be replaced If the filter is dark or looks dirty replace with a new one Also check the rest of the fuel system for contamination 430VP206 P www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 6 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Element Removal e Push down the latches A and remove the air cleaner case B e Remove Paper Element A Foam Element B 430VP313 P Air Element Installation e Install the element correctly on the air cleaner case e Be sure the foam element is in place in the air cleaner case e Be sure the paper element is in place in the air cleaner case e Install the air cleaner case on the air cleaner body e Be sure the latches of air cleaner case are in place in the air cleaner body e Be sure that the hollows A of the air cleaner case and projection B of the air cleaner body are fitting Air Element Cleaning and Inspection NOTE O In dusty areas the elements should be cleaned more frequently than the recommended intervals AAWARNING Because of the danger of highly flammable liquids do not use gasoline or a low flash point solvent to clean the element 430VP207 P www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 7 Periodic Maintenance Procedures e Remove the foam element and the paper element e Clean the foam
76. is recommended to reduce fire danger A commercial solvent commonly available in North America is Standard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent 8 Gasket O Ring Do not reuse a gasket or O ring once it has been in service The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks 9 Liquid Gasket Non Permanent Locking Agent Follow manufacturer s directions for cleaning and preparing surfaces where these compounds will be used Apply sparingly Excessive amounts may block engine oil passages and cause serious damage An example of a non permanent locking agent commonly available in North America is Loctite Lock n Seal Blue 10 Press A part installed using a press or driver such as a journal should first be coated with oil on its outer or inner 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 i
77. it aaa 7 11 Connecting Rod Installation diodes 7 11 Crankshaft Removal coxicioii a ante 7 11 Crankshaft Installation dto iio aorta dd EN 7 11 GCleaning Inspection incitan ii de 7 11 Gonne cting Rod BendTWiSt orita catala didas 7 11 Connecting Rod Big End Crankpin Width Wear o oocncccninnncnnnccnnncnnnccnccnnnnnnonn nano cono cronica cnn cnn narran 7 12 Connecting Rod Big End Bearing Crankpin Weabl ce ccecceeeeeeeeeeeeeeeaeeeeeceeeeaeeeaeeeaeeseeeseeeeeaeeteesneeeeaeetieeseneseaeen 7 12 Crankshatt RUNOUtAxiett tia OR at ee Pelee tthe ela aaa eee eae 7 13 Crankshaft Main Journal Weab ccsccceccessceesceceeeeeseeesneeseeceaeneaneesaesaesaeneneecaaesaeneaeesaaeseessaeaesaeseeeseeeeeseeeseesneneeaaes 7 13 GCrankpinR SIZIAG incide 7 13 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 2 CAMSHAFT CRANKSHAFT Exploded View KG02000BW4 C T1 5 9 N m 0 60 kgf m 52 in Ib T2 25 N m 2 6 kgf m 19 ft lb T3 See Engine Top End chapter O Apply engine oil G Apply grease M Apply molybdenum disulfide grease SS Apply silicone sealant S Follow the specific tightening sequence www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 7 3 Specifications Item Service Limit Camshaft Tappet Cam lobe height Intake 29 131 mm 1 1469 in Exhaust 29 131 mm 1 1469 in Camshaft journal diam
78. ization is admitted via the pilot air jet in the mouth of the carburetor The fuel air mixture passes into the bore of the carburetor side stream of the throttle valve through the bypass holes and pilot outlet While the throttle valve is almost closed it covers the small bypass holes opening into the bore from the pilot system As the throttle valve begins to open it uncovers the bypass holes allowing more fuel air mixture to flow The extra flow is needed because the engine starts to run faster as the throttle is opened The pilot screw controls the amount of fuel air mixture allowed through the pilot outlet but does not meter the bypass holes A moderate amount of air comes in around the throttle valve at idle so adjusting the pilot screw changes the fuel air ratio Turning the pilot screw Idle mixture screw out Counterclockwise enriches the mixture turning it in clockwise leans the mixture Main Fuel Flow KCOS005BS2 Pilot Fuel Flow gt www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 9 Carburetor Low Idle Speed Adjustment O Refer to Low Idle Speed Adjustment in the Periodic Maintenance Chapter 2nd chapter High Idle Speed Adjustment O Refer to High Idle Speed Adjustment in the Periodic Maintenance Chapter 2nd chapter High Altitude Operation At high altitude the standard carburetor air fuel mixture will be excessively rich Performance will dec
79. just valve clearance Adjust Replace Clean or replace Clean Adjust Replace Replace Replace Replace gasket Retighten or replace gasket Clean Clean Correct Replace Clean or replace Bore or replace Replace Tighten Tighten Replace Replace Adjust Change Clean Adjust See engine loss power Replace www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 9 6 TROUBLESHOOTING Starter Motor Troubleshooting Guide 1 Disconnect spark plug caps from the spark plugs 2 Turn engine switch to START position and check condition AWARNING Engine may be cranked in this test Do not touch any rotating parts of engine and equipment during test CAUTION If starter does not stop by engine switch OFF disconnect negative lead from battery as soon as possible STARTER DOES NOT ROTATE Is click sound from solenoid switch NO gt Faulty battery Faulty leads or connection OMelted fuse Faulty engine switch Faulty solenoid switch Weak battery Faulty leads or connection Solenoid to motor Faulty solenoid switch Main terminal in solenoid Faulty starter motor STARTER ROTATES BUT SLOW Is battery normal and well charged YES Faulty leads or connection Solenoid to motor Faulty solenoid switch Main terminal in solenoid Faulty starter
80. lap the valves e Check the seats for good contact all the way around with machinist s g dye E A e Measure the seat width A If it is more than the STD width the seating surface should be refaced e l the valve seating pattern is not correct repair the seat KEO5002BS1 C e Coat the seat with machinist s dye e Fit a 45 cutter A to the holder and slide it into the valve guide O Resurface the valve seat with a 45 cutter removing only enough material to produce a smooth and concentric seat CAUTION Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylinder head must be replaced Do not turn the cutter counterclockwise or drop it against the seat or it will be dulled e Use a 32 seat cutter A to narrow the seat width to the STD width O Turn the seat cutter one turn at a time while pressing down very lightly Check the seat width after each turn CAUTION The 32 cutter removes material very quickly Check the seat width frequently to prevent over grinding NOTE O Keep the seat width as close as possible to the STD width e Make a light pass with the 45 cutter to remove any possible burrs at the edge of the seat e After resurfacing the seat inspect for even valve seating O Apply a machinist s dye to the
81. le speed adjustment should be made after the idle speed adjustment is performed CAUTION Do not adjust high idle speed with the air cleaner removed e Start and warm up the engine throughly AWARNING Always keep your hands clear of the moving parts e Move the throttle lever at a dash to the high idle position and match the lever hole position with the panel hole by inserting 6 mm dia pin or bolt A e Loosen two M6 control panel mounting bolts B enough to move the control panel assembly e Carefully move the control panel assembly right side C up or down to obtain the specified high idle speed High Idle Speed 3600 rpm e Tighten the M6 Mounting bolts Torque Control Panel Mounting Bolts 5 9 N m 0 60 kgf m 52 in Ib e Remove the 6 mm dia pin or bolt e Check the idle speed and readjust the idle speed if necessary CAUTION Be sure to make the idle and high idle speeds respectively correspond to those of the equipment www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 5 Periodic Maintenance Procedures Fuel system Cleanliness Inspection AWARNING Gasoline is extremely flammable and can be explosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove the air
82. m For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 9 Periodic Maintenance Procedures Valve Seat Inspection e Remove the valve see Engine Top End chapter e Inspect the valve seats for damage x If the seats are warped or distorted beyond reconditioning replace A the cylinder head e Pitted or worn valve seats can be refaced Lap the valves to the seats after refacing e Coat the valve seat with machinist s dye e Push the valve into the guide e Rotate the valve against the seat with a lapping tool e Pull the valve out and check the seating pattern on the valve head It must be the correct width A and even all the way around NOTE O The valve stem and guide must be in good condition or this check will not be valid x If the valve seating pattern is not correct repair the seat Valve Seating Surface Width STD Good Too Wide Inlet Exhaust 0 6 0 9 mm 0 024 0 035 in de O Too Narrow Uneven Valve Seat Repair e Follow the manufacturer s instructions for use of valve seat cutters Special Tools Intake Valve Seat Cutter 45 27 5 57001 1114 Outside Cutter 32 28 0 57001 1119 Exhaust Valve Seat Cutter 45 27 5 57001 1114 Outside Cutter 32 25 0 57001 1118 Valve Seat Cutter Holder g6 0 57001 1360 Valve Seat Cutter Holder Bar 57001 1128 x If the manufacturer s instructions are not available use the following procedure Seat
83. ne damage e Check the screen carefully for any damage holes and broken wire x If the screen is damaged replace it www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 7 1 Camshaft Crankshaft Table of Contents Exploded Mi Wii aia eek oe ee lee ele in A Tea 7 2 SpecificationStamiaa dr al tl ie este NESES 7 3 Cruise Eat 7 4 Grankcase Cover Removal nuda cialis 7 4 Crankease Cover Install Maison aia ate 7 4 Inspection aieiai hl eet 7 5 Gladiator ES 7 5 Bree A sti be 7 6 Breather Chamber Cover Removal ic c cc s cgaiecstnacsensapensesavudrescasancadecesoesaacepacessandseesudeadesecoussehensendnesaniasusceiandaecter abs 7 7 Breather Chamber Cover Installation cceeceescessceeeseeeeeecseeseeeeeaeesseecaaeesaeeeaeeeaeeseeseaeesaeesaeesaeeeaeesaeeseeeseaeeseeeneetaas 7 7 Camshaft Tappetino ad sadn cae E dives E da aba eo ta 7 8 Camshaft Tappet Removal ico talado dies brah ioe dentate abe alin eerie 7 8 Camshaft Tappet Installationiw iva Ti a nadine Ae Maal alate ie eal 7 8 Camshatt Disassemblyic 2y aia eka ch ezesnt casera tease epess hha hal E A E aa ds 7 9 Gamshaft Assembly dida tds abi wanderer tii 7 9 Camshaft INspectiom xica e coa 7 9 Camshaft Bearing Jourinal Wear como Ire 7 9 GCrankshatt CONnecina Ra ae ee Ee heh Re SL he i ee te 7 11 Connecting Rod Removal dro
84. ne unless it has been found to be the cause of malfunctioning Engine hard to start Remove spark plug and check spark by cranking engine while having the plug touched against engine block AWARNING Keep the plug as far away as possible from the plug hole To avoid an electric shock do not hold the plug itself Make sure to hold the plug cap YES Check carburetor Is compression sufficient T NO ES gt Faulty spark plug Replace spark plug is replaced o NO Are sparks produced Aa Faulty ignition coil Replace Are sparks produced YES gt when ignition coil is replaced NO gt incorrect air gap Faulty flywheel H Correct Replace Make starting attempts NO a number of times and then remove spark plug and observe electrodes Are they wet YES gt Jo is Check for fuel line Check for plugged air passage Check float level Check carb setting plugged No fuel in the tank OEntry of dust or air into fuel pipe or filter Plugged air hole in tank cap and fuel pump Plugged fuel line Add E Clean H Clean Clean Excessive use of choke Plugged air cleaner eToo high fuel level in float bowl t Remove the plug and turn the crankshaft without loading E Clean E Adjust
85. nt during assembly www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 1 General Information Table of Contents Before Servicing its ivtanit aac ev edie ea a erect eae 1 2 Model Identification cionado tcs ill 1 4 General Specifications ii e Medd en ee 1 5 Torque and Mocking Agata ai tia 1 6 Special Tod Suri dt a tibias 1 8 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 1 2 GENERAL INFORMATION Before Servicing Before starting to service the engine carefully read the applicable section to eliminate unnecessary work Photographs diagrams notes cautions warnings and detailed descriptions have been included wherever necessary Nevertheless even a detailed account has limitations a certain amount of basic knowledge is required for successful work Especially note the following 1 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 th
86. nt experience or doubts as to his ability to do the work all adjustments maintenance and repair should be carried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thoroughly familiarize yourself with the procedures before starting work and then do the work carefully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may adversely affect safe operation To get the longest life out of your engine e Follow the Periodic Maintenance Chart in the Service Manual e Be alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki engine parts Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual carefully Don t take shortcuts e Remember to keep complete records of maintenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major sys tems and these systems make up the manual s chapters The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chap ter in turn has its own comprehensive Table of Contents For example if you want ignition coil information use the Quick Reference Guide to locate
87. nto fuel filter or fuel pipe Engine malfunctions at low speed Remove spark plug and check spark by cranking engine while having the plug touched against engine block HE WEAK gt STRONG AWARNING Keep the plug as far away as possible from the plug hole To avoid an electric shock do not hold the plug itself Make sure to hold the plug cap gt YES muffler i Is unusual smoke emitted out of gt Directly and gradually open throttle valve by hand Does the revolution drop or does engine stall at a certain position Is air sucked through carburetor or intake manifold flanges E Y i Are valve clearances of normal values YES Replace Clean Replace Correct Faulty plug insulation Fouled electrodes Faulty ignition coil lncorrect air gap ES A O Overrich fuel in pilot system Turn in pilot screw by a minor extent Disassemble and clean Plugged in carburetor interior Loose flange nuts Damaged gasket Retighten Replace Compression leakage Wrong valve timing Adjust valve clearance Correct alignment of timing gear marks Y Is alignment of timing gear marks NO OLargely deviated valve timing Correct alignment of correct timing gear marks www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 TROUBLES
88. odic Maintenance chapter Governor Arm Removal e Remove Control Panel Assembly e Loosen the clamp nut A and take off the governor arm B e Unhook the throttle link rod spring C end loop and clear the throttle link rod lower end D 430VP304 P pS www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 6 FUEL SYSTEM Governor Link Mechanism Governor Arm Installation e Install the governor arm A onto the governor shaft B temporarily e Be sure the link spring C around the throttle link rod D is in place and that it pulls the governor arm and throttle lever E toward each other e Loosen the clamp nut F on the governor arm enough to move the governor shaft e Turn the top end of the governor arm counterclockwise to fully open the carburetor G throttle valve and hold it there e Turn the governor shaft counterclockwise fully turn the shaft to end of its travel e Tighten the clamp nut Torque Governor Arm Clamp Nut 7 8 N m 0 80 kgf m 69 in Ib e Install the control panel assembly and connect the governor arm with the governor spring Governor Assembly Removal e Remove the crankcase cover see Camshaft Crankshaft chapter e Remove the push rod see Engine Top End chapter e Invert the engine e Remove the camshaft A e Remove Washer A Snap Ring B Sleeve C Governor Plate D Snap Ring B Steel balls E Ball Guide F
89. of the relief valve e Install the mounting bolts and tighten them Torque Oil Pump Cover Plate Mounting Bolts 5 9 N m 0 60 kgf m 52 in lb Oil Pump Relief Valve Inspection e Remove the oil pump see Oil Pump Relief Valve Removal e Visually inspect the pump gear outer and inner rotor and cover plate x If there is any damage or uneven wear replace them O Check the clearance A between the inner and outer rotor with a feeler gauge Measure the clearance between the high point of the inner rotor and the high point of the outer rotor x If the measurement exceed the service limit replace the rotors as a set Inner and Outer Rotor Clearance Service Limit 0 2 mm 0 008 in e Measure the outside diameter A of the outer rotor with a micrometer at several points x If the rotor diameter is less than the service limit replace both the inner and outer rotor Outer Rotor Outside Diameter Service Limit 40 470 mm 1 5933 in e Measure the thickness B of the outer rotor with a micrometer at several points x If the rotor thickness is less than the service limit replace both the inner and outer rotor KFO7001BS1 Outer Rotor Thickness Service Limit 9 830 mm 0 3870 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 8 LUBRICATION SYSTEM Oil Pump Relief Valve e Measure the inside diameter A of the pump housing with an inside micrometer a
90. olts Bolts Starter Motor Mounting Bolts Starter Motor Through Bolts Recoil Starter Mounting Nuts Recoil Starter Retainier Screw Spark Plugs The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners Threads dia ft lb 17 in lb 30 in lb 52 in lb 11 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 1 8 GENERAL INFORMATION Special Tools Piston Ring Pliers 57001 115 Piston Ring Compression Belt 955 67 57001 1096 Valve Seat Cutter 45 027 5 57001 1114 Valve Seat Cutter 32 025 0 57001 1118 Oil Pressure Gauge Adapter PT 1 8 57001 1033 Valve Seat Cutter 32 028 0 57001 1119 Piston Ring Compression Grip 57001 1095 Valve Seat Cutter Holder Bar 57001 1128 Ss www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 9 Special Tools Compression Gauge Adapter M14 x 1 25 57001 1159 Kawasaki Bond Silicone Sealant 56019 120 Oil Filter Wrench 57001 1249 Valve Seat Cutter Holder 6 57001 1360
91. piston rings are worn unevenly or damaged replace them x If the ring grooves are worn unevenly or damaged replace both the piston and piston rings e Check ring grooves for wear by inserting a new ring in the proper groove at several points around the piston e Measure the clearance between the top and second rings and their grooves using a thickness gauge A x If the piston ring groove clearance is greater than the specified value replace the piston Piston Ring Groove Clearance Service Limit Top 0 18 mm 0 007 in Second 0 18 mm 0 007 in NOTE The oil ring is a three piece assembled ring It is difficult to measure the ring groove clearance and thickness visually inspect only e Measure the piston ring thickness A O Use a micrometer to measure at several points around the rings x If any of the measurement are less than the service limit replace the entire set of rings Piston Ring Thickness Service Limit Top Second 1 40 mm 0 055 in NOTE O When using new rings in a used piston check for uneven groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 16 ENGINE TOP END Cylinder Piston Piston Ring End Gap e Remove the piston rings e Push each ring one at a time in the cylinder bore to a point close to the bottom of the cylinder bore O Us
92. que Oil Drain Plug 6 9 N m 0 70 kgf m 61 in Ib e Remove the oil filler cap and pour in the specified type and amount of oil Engine Oil Type SF SG SH or SJ Class Viscosity SAE40 SAE30 SAE10W 30 SAE10W 40 or SAE5W 20 Capacity When filter is not removed 1 5 L 1 6 US qt When filter is removed 1 7 L 1 8 US qt NOTE O Some increase in oil consumption may be expected when a multi grade engine oil 10W 30 10W 40 5W 20 is used Check the oil level frequently Oil Filter Change e Using a strap wrench or oil filter wrench A remove the oil filter B Special Tool Oil Filter Wrench 57001 1249 O When unscrewing the oil filter place a suitable container beneath the oil drip tray to receive oil from the oil filter and oil passages in the engine Turn the filter counterclockwise to remove it Oil Filter Installation e Apply light film of engine oil to the seal A e Install new filter O Turn the filter until the seal contacts mounting surface B of the engine Then turn the filter BY HAND S 3 4 turn more e Run the engine at slow idle speed 2 minutes Check for leaks around the engine e Stop the engine Check the oil level see Oil Level Inspection lt Ambient Temperature _ gt 20 C 10C OC i 20C 30C 40 C pinz a gun gt SAE1OW 30 SAE10W 40 AF 14 F 32 F 50F 68F 86F 104F www mymowerparts com For Kawasaki Discount Parts C
93. r low flash point solvents If cleaning does not solve the problem replace the relief valve parts x If necessary put the ball in position and lightly tap the ball with a suitable tools to form a perfect seat e Measure free length A of the spring with a vernier caliper x If the free length of the spring is less than the service limit replace the spring Relief Valve Spring Free Length Service Limit 19 50 mm 0 77 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LUBRICATION SYSTEM 6 9 Oil Screen Oil Screen Removal e Remove the crankcase cover see Camshaft Crankcase chapter e Unscrew the mounting bolts A and remove the oil pump parts assembly e Remove the oil screen B Oil Screen Installation e Clean the oil screen thoroughly whenever it is removed for any reason e Insert the oil screen A in position and install the oil pump parts assembly see Oil Pump Relief Valve Installation 430VP608 P Cleaning and Inspection e Clean the oil screen with high flash point solvent and remove any particles stuck to it AAWARNING Clean the screen in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents NOTE O While cleaning the screen check for any metal particles that might indicate internal engi
94. rease and fuel consumption will increase High altitude performance can be improved by installing a smaller diameter main jet in the carburetor and correct idle speed NOTE O The main jet high altitude kits are available if the equipment is to be used in the high altitudes The main jet numbers are stamped on ends of the main jets High Altitude Main Jet Main Jet No Altitude FH380V FH430V 0 1000 m 0 3 000 ft 78 88 1 000 2 000 m 3 000 6 000 ft 75 85 2 000 m 6 000 ft and higher 72 82 Main Jet Replacement e Place the engine equipment on a level surface e Close the fuel shut off valve in the equipment e Remove the carburetor see Carburetor Removal e Unscrew the float chamber mounting bolt A and take off the float chamber B and gasket 430VP307 P e Using a properly sized blade screw driver carefully replace the main jet A with a new one for altitude expected e Tighten the main jet to the specification see Carburetor Disassembly Assembly Notes e Install the float chamber and gasket e Tighten float chamber mounting bolt 430VP308 P Fuel system Cleanliness Inspection O Refer to Fuel System Cleanliness Inspection in the Periodic Mainte nance Chapter 2nd chapter www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 10 FUEL SYSTEM Carburetor Carburetor Removal AAWARNING Gasoline is extremely flammable and c
95. ring end gap Piston pin outside diameter Piston pin hole inside diameter Item Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Top Second Top Second Top Second Oil Connecting rod small end inside diameter Cylinder inside diameter Cylinder bore out round Standard Cylinder 0 50 mm Oversize Service Limit 390 kPa 57 psi MIN 0 03 mm 0 001 in 0 35 mm 0 014 in 0 05 mm 0 002 in 5 95 mm 0 0234 in 5 93 mm 0 0233 in 6 08 mm 0 239 in 31 5 mm 1 24 in 0 5 mm 0 02 in 64 79 mm 2 551 in 0 18 mm 0 007 in 0 18 mm 0 007 in 1 40 mm 0 055 in 0 75 mm 0 029 in 0 75 mm 0 029 in 1 05 mm 0 041 in 15 96 mm 0 628 in 16 08 mm 0 633 in 16 05 mm 0 632 in 65 10 mm 2 563 in 65 60 mm 2 583 in 0 056 mm 0 0022 in Valve clearance Valve seating surface angle Valve seating surface width Valves guide inside diameter Cylinder bore diameter standard cylinder Standard cylinder 0 50 mm Over size Item Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Standard 0 10 0 15 mm 0 004 0 006 in 45 0 6 0 9 mm 0 024 0 035 in 6 00 6 012 mm 0 2362 0 2367 in 65 00 64 98 mm 2 559 2 558 in 65 50 65 48 mm 2 579 2 578 in Special Tools Compression Gauge 57001 221 Compression Gauge Adapter M14 x 1 25 57001 1159 Piston Ring Pliers 570
96. rparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 12 FUEL SYSTEM Carburetor Carburetor Cleaning AWARNING Clean the carburetor in a well ventilated area and take care that there is no sparks or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean the carburetors CAUTION Do not use compressed air on an assembled carburetor or the floats may be crushed by the pressure Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carburetor with a cleaning solution This will prevent to damage or deterioration of the parts The carburetor body has plastic parts that cannot be removed Do not use a strong carburetor cleaning solution which could attack these parts instead use a mild high flash point clean ing solution safe for plastic parts Do not use wire or any other hard instrument to clean carbu retor parts especially jets as they may be damaged e Disassemble the carburetor e Immerse all the carburetor metal parts in a carburetor cleaning solution and clean them e Rinse the parts in water and dry them with compressed air e Do not use rags or paper to dry parts Lint may plug the holes or passages e Blow air through the holes and fuel passages with the compressed air All holes must be open e Assem
97. rque Recoil Starter Retainer Screw 7 8 N m 0 80 kgf m 69 in Ib e Turn the reel two turns counterclockwise to preload the recoil spring www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 8 23 Starter System e While holding the reel to keep it from unwinding feed the end of the rope through the hole in the case e Clip the rope as shown to hold it e Install the handle A and secure it with a knot B e Remove the clip C to release the rope www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING 9 1 Troubleshooting Table of Contents Engine Troubleshooting Guide rss aee rasa dein dna thd oad 9 2 Starter Motor Troubleshooting Guide cccecceceeecceescecseeeeeeeeseeeseeeeeeeeeeeeseeeaeeenaessaeseaeeseesaeseaaeeeeseaeseaaeeaeesnarseaeseneeeneeeaas 9 6 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 9 2 TROUBLESHOOTING Engine Troubleshooting Guide If the engine malfunctions check if the way the engine is used is correct If engine malfunctions even if engine is used correctly systematically carry out troubleshooting starting with simple points This chart describes typical troubleshooting procedures Do not unnecessarily disassemble carburetor magneto or engi
98. s com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 8 FUEL SYSTEM Carburetor Fuel and Air Flow The main system of the carburetor consists of the main jet A main nozzle B and the main air passage C main air jet D The main system meters fuel to the engine during moderate to heavy load conditions Fuel flows through the main jet and into the main nozzle where it is joined by air from the main air passage main air jet The resulting mixture flows out the end of the main nozzle into the carburetor bore where it is atomized by the high speed air flow and carried into the engine Main System Fuel and Air Supply Le SY u Carburetor Bore R KC05004BS2 C The pilot system includes the pilot jet E pilot screw F Idle mixture Pilot System Fuel and Air Suppiy screw pilot air jet G pilot outlet H and the bypass holes I The pilot system meters the fuel air mixture while the engine is idling and running under a light load Under these conditions there is very little air flow through the carburetor bore so little that it is not enough to draw fuel through the main system of the carburetor and atomize it Instead the fuel is drawn through the pilot system since the nearly closed throttle valve J causes high speed air flow past the pilot outlet and bypass holes even at low engine speed Fuel flow in the pilot system is metered by the pilot jet Air for better atom
99. s in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended This manual makes reference to molybdenum disulfide grease MoS2 in the assembly of certain engine parts Always check manufacturer recommendations before using such special lubricants 17 Electrical Wires All the electrical wires are either single color or two color and with only a few exceptions must be connected to wires of the same color On any of the two color wires there is a greater amount of one color and a lesser amount of a second color so a two color wire is identified by first the primary color and then the secondary color For example a yellow wire with thin red stripes is referred to as a yellow red wire it would be a red yellow wire if the colors were reversed to make red the main color ed Wire Strands Yellow Red Yellow Red 6B020601W1 C 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
100. sette is sticking with the reel be careful that the cassette does not drop Be careful that the recoil spring does not fly loose from the cassette and cause injury The spring is under great pressure e Slowly lift the recoil spring cassette straight up out of the case or reel x If the recoil spring A must be removed from the cassette B hold the cassette with the opening side facing downward in a suitable container and tap the cassette to remove the recoil spring www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 22 ELECTRICAL SYSTEM Starter System Recoil Starter Assembly AWARNING Wear gloves during the recoil spring installation to avoid injury The recoil spring must be assembled with great pressure e Lightly grease the recoil spring e Set the recoil spring into the spring cassette e Wind the rope clockwise A on the reel and hold the rope end B with tape e Install the spring cassette C on the reel so that the tongues D on the cassette fit in the openings in the reel e Lightly grease the shaft A e Put the reel into the case with the round peg B aligned with the spring inner tongue C e Turn the reel clockwise until you feel the hang hook on the catch e Install Return Springs A and Pawls B Washer C and Center Spring D e Lightly grease the center spring e Install Retainer A Washer B Screw C To
101. sition is not correct replace the float with a new one KCO5007BS1 C e Inspect the float valve for excessive wear or damage The tip should be smooth without any grooves scratches or tears The rod at the other end of the needle should move smoothly when push in and released x If either the needle or the seat is worn or damaged replace the float assembly and carburetor body as a set Good Bad e Inspect the tapered portion A of the pilot screw B for wear or damage x If the pilot screw is worn or damaged on the tapered portion replace it e Check the spring for weakened condition replace it if necessary KCO5008BS1 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 14 FUEL SYSTEM Intake Manifold Intake Manifold Removal e Remove Air Cleaner see Cleaner Body Removal Engine Upper Cover Carburetor see Carburetor Removal e Remove the harness from the clamps A on the intake manifold e Unscrew the manifold mounting bolts B Intake Manifold Installation e Replace the O rings A with new ones e Clean the mating surfaces of the cylinders and intake manifolds e Clean the mating surfaces of the carburetor and intake manifold and install the new gaskets A and intake manifold e Tighten the mounting bolts following the tightening sequence Torque Intake Manifold Mounting Bolts 6 9 N m 0 70 kgf m 61 in Ib
102. st the valve clearance www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 8 ENGINE TOP END Cylinder Head Push Rod Inspection e Place the rocker arm push rod in V blocks that are as far apart as possible and set a dial gauge on the rod at a point halfway between the blocks Turn the rod to measure the runout The difference between highest and the lowest dial readings is the amount of runout If the runout exceeds the service limit replace the rod Rocker Arm Push Rod Runout Service Limit 0 5 mm 0 02 in Valve Mechanism Removal installation e Remove the cylinder head assembly see Cylinder Head Assembly Removal NOTE O When removing the valve mechanism parts note their position so that they may be reinstalled in their original position during assembly e Remove Valve Clearance Adjusting Nuts A Rocker Arms B e Support the valve head in the combustion chamber with a suitable block e To remove the collets A push down the valve retainer B with thumbs and remove the Collets e Remove the spring C and valve D e Remove the stem seals A NOTE O It is not necessary to remove the stem seal unless it is being replaced O Valve guide B is not replaceable do no remove it e Valve Installation O Apply engine oil to the valve stem to avoid damaging the stem seal O Check to see that the valve moves smoothly up and
103. t in with the marks facing out Seals should be pressed into place using a suitable driver which contacts evenly with the side of seal until the face of the seal is even with the end of the hole 13 Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips Before a shaft passes through a seal apply a little oil preferably high temperature grease on the lips to reduce rubber to metal friction 14 Circlip Retaining Ring Replace any circlips and retaining rings that were removed with new ones as removal weakens and deforms them When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 3 Before Servicing 15 Cotter Pin Replace any cotter pins that were 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 grease
104. t several points x lf the inside diameter is more than the service limit replace the crankcase cover Pump Housing Inside Diameter Service Limit 40 801 mm 1 6063 in e Measure the depth B of the pump housing with a depth micrometer at several points If any of measurement is more than the service limit replace the 3 crankcase cover gt Q 430VP604 P Pump Housing Depth Service Limit 10 230 mm 0 4028 in e Measure the outside A diameter of the pump shaft with a micrometer at several points x If the diameter is less than the service limit replace the pump shaft Pump Shaft Outside Diameter Service Limit 10 923 mm 0 4300 in e Measurer the inside diameter A of the pump shaft bearing in the crankcase cover with a inside micrometer at several points x lf the inside diameter is more than the service limit replace the crankcase cover Pump Shaft Bearing Inside Diameter Service Limit 11 072 mm 0 4359 in ASOVP605 P e Visually inspect the relief valve spring steel ball and valve seat in the crankcase cover x If any rough spots are found during above inspection wash the valve clean with a high flash point solvent and blow out any foreign particles that may be in the valve with compressed air WARNING Clean the parts in a well ventilated area and take care that there is no spark or flame anywhere near the working areas Because of the danger of highly flammable liquids do not use gasoline o
105. tenance Chapter 2nd chapter www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 8 17 Starter System Starter Motor Removal e Remove the mounting bolts A and pull the starter motor B from the engine Starter Motor Installation e Clean the starter motor and engine mounting flanges to ensure good electrical contact and tighten the mounting bolts Torque Starter Motor Mounting Bolts 15 N m 1 5 kgf m 11 0 ft Ib Starter Motor Disassembly e Remove Through Bolts A Brush Plate B Yoke C Cap D e Wrap a cloth around the Pinion assembly Then holding it on a vise with alminum plates A placed in between and remove the nut e Remove Washer A Spring B Collar C Pinion Assembly D Washer E Slider F Bracket G Armature H Washer I Conical Spring Washer J KHO9000BS1 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 18 ELECTRICAL SYSTEM Starter System Starter Motor Assembly e Assembly is the reverse of disassembly e Apply a small amount of grease to the armature shaft A KHO9001BS1 C e Press the springs and holding the brush leads with suitable clips e Fit the brush assembly A into the armature B e Fit the projection C on the brush assembly into the notch D in the yoke e Check the cap and replace it with a new one if dama
106. than the service limit replace the connecting rod Connecting Rod Big End Width Service Limit 18 80 mm 0 74 in e Measure the crankpin width A with a dial caliper If the crankpin width is more than the service limit replace the crankshaft Crankpin Width Service Limit 39 50 mm 1 56 in Connecting Rod Big End Bearing Crankpin Wear e Apply a light film of oil on the thread of the cap bolts e Install the cap bolts and tighten the bolts to the specified torque see Piston Installation in Engine Top End chapter e Measure the inside diameter A of big end at several points with a telescoping gauge or inside micrometer x lf the inside diameter is more than the service limit replace the connecting rod with a new one Connecting Rod Big End Inside Diameter Service Limit 33 055 mm 1 301 in e Measure the crankpin outside diameter A O Use a micrometer to measure several points around the crankpin circumference x If the crankpin diameter is less than the service limit replace the crankshaft with a new one Crankpin Outside Diameter Service Limit 32 94 mm 1 297 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 7 13 Crankshaft Connecting Rod Crankshaft Runout e Measure the crankshaft runout O Set the crankshaft in a flywheel alignment jig or on V blocks gauge O Set a dial gauge against both bearing journals O Turn the cranks
107. the Electrical System chapter Then use the Table of Contents on the first page of the chapter to find the Ignition coil section Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices AWARNING 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 x 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 Contents In these illustrations you will find the instructions indicating which parts require specified tightening torque oil grease or a locking age
108. the engine over with the throttle fully open until the compression gauge stops rising Electric Starter Model Cylinder Compression MIN 390 kPa 57 psi O Cylinder compression reaches more than 1000 kpa 145 psi in a case when cranking speed is over 700 rpm e Repeat the measurement to the other cylinder x If the compression is higher than the specified value the piston rings cylinder and valves are probably in good condition If the compression is too high check the following 1 Carbon build up on the piston crown and cylinder head clean off any carbon on the piston crown and cylinder head 2 Cylinder head gasket use only the proper gasket The use of a gasket of incorrect thickness will change the compression 3 Valve guides and piston rings rapid carbon accumulation in the combustion chamber may be caused by worn valve guides and or worn piston oil rings This may be indicated by white exhaust smoke x If cylinder compression is lower than the MIN check the following 1 Gas leakage around the cylinder head replace the damaged gasket and check and check the cylinder head warp Condition of the valve seating Valve clearance Piston cylinder wear piston seizure Piston ring piston ring groove nan www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 6 ENGINE TOP END Cylinder Head Cylinder Head Assembly Removal e Remove Air Cleaner and Carburetor see Fuel
109. tive Ignition Assemblies Permanent Magnet Flywheel Spark Plugs Stop Switch D1 SW CW Rotation KHO7002BW2 C Co Core Lamination R1 Control Resistor D1 Diode TS1 Trigger Sensor L1 Primary Coil SP Spark Plug L2 Secondary Coil SW Stop Switch Q1 Transistor F Flywheel B Base M Magneto C Collector N North Pole E Emitter S South Pole Ignition Theory of Operation Mounted to the periphery of a flywheel are a pair of magnetic poles south leading in clockwise rotation generated by a permanent magnet By rotating the flywheel magnetic poles clockwise past the ignition module on a laminated core group a voltage is generated in the primary winding L1 This generates a small bias current to flow through the control resistor R1 to the base of Q1 This base drive causes the transistor to conduct turns on completing the primary circuit Current flows from the high side of the primary winding through the transistor collector to emitter to ground The trigger sensor TS1 senses the optimum time peak current to remove the base drive from the transistor Q1 This abrupt turning off of the transistor causes an interruption in current flow which allows its associated flux collapse and several hundred volts is induced through the primary winding L1 inducing a very large voltage in the secondary winding L2 When the secondary voltage reaches several thousand volts the spark plug SP gap is ionized and
110. tor leads are loose or open x If the output voltage dose not rise as the engine speed increase the regulator is defective or the alternator output is insufficient for the loads Regulated Output Voltage Battery Voltage to 15 VDC 3600 rpm www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 12 ELECTRICAL SYSTEM Charging Ignition System Stator Coil Resistance e Disconnect the connector A e Measure the stator coil resistance Electric Starter Model O Connect an ohmmeter between stator pins B Stator Coil Resistance Electric Starter Model 0 01 to 0 1 Q Recoil Starter Model with Electric Clutch O Connect an ohmmeter between stator pin and engine body Stator Coil Resistance Recoil Starter Model with Electric Clutch 4 4 to 15 Q x If the meter does not read as specified replace the stator coil x If the coil has normal resistance but the voltage inspection showed the alternator to be defective the flywheel magnets have probably weakened and the flywheel must be replaced e Check for continuity between each stator pin and ground There should be no continuity infinite ohm x If the stator coil fails any of these tests replace the coil with a new one Unregulated Stator Output e Disconnect the connector A e Connect AC voltmeter to the stator pins B e Start the engine Run the engine at the 3 000 rpm speed e Voltage reading should be minimum 26 VAC 3 00
111. using B 430VP801 P e Remove Ignition Coils see Ignition Coil Removal Stud Bolts A e Hold the flywheel with a suitable tool remove the flywheel bolt and washer S iee P e Using a suitable flywheel puller A remove the flywheel B CAUTION Always use flywheel puller www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 10 ELECTRICAL SYSTEM Charging Ignition System e Remove Woodruff Key A Stator Coil Lead Connector B Stator Coil Screw C Stator Coil D Flywheel Stator Coil Installation e Install the stator coil and tighten the screws Torque Stator Coil Screws 3 4 N m 0 35 kgf m 30 in Ib e Using a cleaning fluid clean off any oil or dirt on the following portions and dry them with a clean cloth A Crankshaft Tapered Portion B Flywheel Tapered Portion e Fit the Woodruff key C securely in the slot in the crankshaft before installing the flywheel e Install the flywheel onto the crankshaft taper so that the woodruff key fits in the key way in the hub of the flywheel e Install the fan A so that two positioning bosses B fit around flywheel ignition magnet C e Install the plate D so that the notch E inserts into the slot in the flywheel e Install the screen A so that the projections B fit into the recess C of the fan Recoil starter model e Install the pulley or bracket A so that the tabs o
112. valve face insert the valve and snap it closed against the seat several times The valve surface should show good contact all the way around Be sure the valve seat is centered on the valve face The position of the valve in the seat is evident after lapping the valve x If the seat does not make proper contact lap the valve into seat with a vacuum cap tool www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 11 Periodic Maintenance Procedures e Coat the face of valve sparingly with a fine lapping compound e Use the vacuum cup tool A to grip top of the valve B Rotate the valve in a circular motion to lap the valve to the seat e Lift the valve slightly from the seat every 8 to 10 strokes continue lapping operation until a uniform ring appears around entire surface of the valve face e When lapping is completed wash all parts in solvent to remove lapping compound Dry the parts thoroughly e Note the position of the lapping mark on the valve face The lapping mark should appear on or near the center of the valve face e When the engine is assembled be sure to adjust the valve clearances see Valve Clearance Adjustment Lubrication System Oil Level Inspection e Place the engine on a level surface e Remove the oil filler cap A and wipe its dipstick B with a clean cloth e Insert the dipstick into tube C without screwing it in then check the

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