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KEL26A Handheld Edger Service Manual

1. Damper Removal e Remove the damper A and holder B from the housing C O Use of special tools to removable the damper and holder Special Tool Damper Puller 57001 1466 Noticing Points When Using Special Tools O Install the ring remover D to the square holes 2 so that the allen bolts 2 are turned to the bottoms securely O Install the long bolt F to the puller nut E so that it is flush with the holder B O Turn the clamp bolt of the holder B clockwise securely so that the long bolt F is turned to the same direction STS7146XST Installation e Installation is the reverse of removal e Damper and holder installation Push with the vise O Apply soap and water to the damper NOTE Do not apply oils to the damper www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 6 ENGINE Clutch and Fuel Tank Clutch Removal e Keeping the clutch shoes A from turning by using a pair of pliers release the clutch pins B by turning counterclockwise to remove the clutch assembly O Take care not to scratch the clutch shoes A O Do not remove the clutch spring C if not needed Fuel Tank Removal e Remove the stand A and unscrew the remaining mounting screw B of the fuel tank e Loosen the fuel tube clamps to remove the fuel tank C together e Remove the tank grommet A out of the fuel tank Fuel Tank Installation e Installation
2. www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FRAME 2 1 Table of Contents ExplOded Vi Wi potato A td 2 2 C ter aa A si A A A daha 2 4 GuUllerRemova a O or EEEN 2 4 Gutter Installation Moassas N TEE ctseassuneca stata EE ETE E S EEE O 2 4 HOla O A NE 2 5 Handle REMOVAL a a AE E TE O UTS 2 5 aeae EAEE o aA E EE aa E es 2 5 Complete aTe ETT E ET 2 6 Complete Engine Removal eris rn A EA gente ess E E Geile N 2 6 Complete Engine Installation eeeeeesessseseeeceeeteneeeaeceneceneeaeseneceaeeaeceaeesaeseaeceaeesaeeeaeeeaeesaeeeaeseaeesseeeaeesasereeeaeenaes 2 6 Gps ranas 2 7 Complete Grp Removals rotasie o agea paata e da a e deaa es a ad aeiaai 2 7 Complete Grip Installation nern sidrana a a eee ate cena a a a a N aria 2 7 LhrottlesGable Installation a ones dio 2 7 Complete Gear Case Guard and WhEel ccccccceeeceeeeeeceneecesaeesneeeeaeeeseaeeecaeeeaneseeaeeseaeeseeceeseaeeseaeeeeeaeeseeeeteaeesseeeess 2 8 Complete Gear Case Guard and Wheel Removal ccccccececeeeeeeeeeeeeeeaeeeeseeeeaeeeseaeeecaeeseeeeeseaeeseaeeeseaeeseeeeseaeeted 2 8 Complete Gear Case Guard and Wheel Installation cccccceeecccceneeeeeeeeeeaeeeeaeeeceaeeseaeeeeeaeeseaeeesaeeeeaeeseneeeseaeeseas 2 8 Wheel and attached Parts viii aldeas 2 9 Wheel and Attached Parts Removal cccccccnncncoononoconononenonanononnnnnnnnononononnnnnnononnnonnnnnnnnnnnnnnonnnnnnnnnnrnnnnnnn
3. Guard Removal e Remove the three guard clamp nuts A together with the spring washers and flat washers e Remove the three guard clamp bolts A together with the plate B and gear case C from the guard D Gear Case and Attached Parts Installation e Installation is the reverse of removal Torque Guard Clamp Nuts 5 mm 3 4 3 9 N m 0 35 0 40 kg m 30 4 34 7 in Ib Guard Clamp Bolts 5 mm 3 4 3 9 N m 0 35 0 40 kg m 30 4 34 7 in Ib O When attaching the gear case to the guard make sure that the protrusion on the guard comes in contact with the cylindrical portion of the gear case NOTE O Be sure that the guard bolts are not turned together with the nuts when installing www mymowertrparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FRAME 2 11 Gear Case Gear Case Disassembly e Remove the circlips A B out of their respective grooves e Using the special tool remove the shaft I the plate L and the ball bearing G as a unit Special Tool Bearing Puller 57001 1467 O Heat the complete gear case to about 110 C to 140 C 230 F to 280 F on a heating plate to facilitate bearing removal AWARNING Be careful when handling the gear case and related parts as they could be extremely hot and cause serious burns e Pull the bevel gear C off the gear case D together with the bearing E F and the bevel gear H e Strike t
4. 327 0002W4 C T1 M5 3 4 3 9 N m 0 35 0 40 kg m 30 4 34 7 in lb T2 M5 2 0 2 5 N m 0 20 0 25 kg m 17 4 21 7 in lb T3 M4 2 0 2 5 N m 0 20 0 25 kg m 17 4 21 7 in lb T4 M4 1 7 2 0 N m 0 17 0 20 kg m 14 8 17 4 in Ib T5 M8 13 7 15 7 N m 1 40 1 60 kg m 10 1 11 6 ft lb T6 M8 9 8 11 8 N m 1 00 1 20 kg m 7 2 8 7 ft lb T7 M14 11 8 16 7 N m 1 20 1 70 kg m 8 7 12 3 in lb www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 4 ENGINE Housing Clutch Drum and Damper NADIE Stop the engine before disassembling the unit and drain the fuel tank securely Special attention should be paid to prevent burns or fire Housing Removal e Remove the housing A and lead wire B clamp C from crankcases D Screws E Clutch Drum Removal e Remove the clutch drum A from the housing B Circlip C NOTE O Use two types of special tools to removable the clutch drum Special Tools Outside Circlip Pliers 57001 144 Drum Pusher D 24 mm 57001 1440 Clutch Drum Installation e Installation is the reverse of removal e Push with the hand press A NOTE O Apply a bit of grease to the clutch drum shaft Confirm that the clutch drum rotates smoothly after assembles www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE 3 5 Housing Clutch Drum and Damper
5. Handle Handle Removal e Remove the handle C from the main pipe A e Remove Allen bolts B 4 bolts Handle C Collar D Handle Installation e Installation is the reverse of removal Torque Allen Bolts 5 mm 1 5 2 0 N m 0 15 0 20 kg m 13 0 17 4 in Ib O Install the handle so that the end with the larger oval shape is to the left of the cutter blade O Align the handle end face with the label end face F O Install the collar D on the handle position indication label E O Ensure the proper installation angle of the collar by directing its cutout in the horizontal direction and assemble it without infringing on the handle or the bracket www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 6 FRAME Complete Engine Complete Engine Removal e Unscrew the mounting screw A to remove the air filter cap B e Remove the cable end nipple A out of the throttle valve terminal B e Remove the lead wire connectors C D e Release the clamp Bolt A Complete Engine Installation e Installation is the reverse of removal O Apply a thin coat of molybdenum disulfide grease to the outer periphery A of the cable opening at the engine O Make sure that the cable opening is securely inserted into the holes of the outer periphery engine drum housing and the pipe ends touched the bottom of holder as well Both are confirmed by the CLICK sound
6. Inferior of check valve Replace Clogged air cleaner element Clean Inferior of manifold o ring Replace Poor tightening of carburetor screw Tighten Damaged carburetor control metering lever Replace Malfunction of carburetor control metering lever Replace Deformation of carburetor control metering lever spring Replace Poor installation of control lever spring Correct Damaged main diaphragm button Replace Inferior of main diaphragm gasket Replace Poor tightening of main diaphragm cover Tighten Damaged main diaphragm Replace Inlet needle valve wear Replace Foreign matter sticking of inlet needle Clean www mymowertrparts com
7. O Install the gear case shaft so that it forms a right angle with the direction of the engine cylinder www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FRAME 2 7 Grip Complete Grip Removal e Loosen the two grip retaining bolts C and pull out the grip B from the main pipe A Main Pipe A Grip B Clamp Bolt C Throttle Lever D 327 000581 Complete Grip Installation e Installation is the reverse of removal Torque Allen Bolt 5 mm 1 5 2 0 N m 0 15 0 20 kg m 13 0 17 4 in Ib O To ensure the proper circumferential direction of the grip install the grip so that the direction of the throttle lever forms a right angle with the direction of the gear case shaft mb P SA TETS La ZW 327 0006N1 C 201 327 0012W1 C Throttle Cable Installation e Installation is the reverse of removal Adjust the carburetor adjustment screw B so that the play A of the throttle cable is approximately 1mm 0 04 in maximum when the throttle lever on the grip is in its idle position about1 0 mm 0 04 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 8 FRAME Complete Gear Case Guard and Wheel Complete Gear Case Guard and Wheel Removal e Remove the clamp bolt B and alignment bolt C from the gear case A and pull out the complete gear case from the main pi
8. Before Servicing 15 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film During assembly oil or grease whichever is more suitable should be applied to any rubbing surface which has lost its lubricative film Old grease and dirty oil should be cleaned off Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles Don t use just any oil or grease Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended This manual makes reference to molybdenum disulfide grease MoS2 in the assembly of certain engine parts Always check manufacturer recommendations before using such special lubricants 16 Replacement Parts When there is a replacement instruction replace these parts with new ones every time they are removed There replacement parts will be damaged or lose their original function once removed 17 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure 18 Specifications Specification terms are defined as follows Standards show dimensions or performances which brand new
9. O Take care not to damage the oil seals O Take care not to lose the adjusting shims D 0 to 1 piece Crankcase and Crankshaft Installation The crankshaft the connecting rod and the needle bearing are inseparable This means that the crankshaft must always be replaced as a complete unit in the event of damage to any one of these parts when fitting a replacement always install new ball bearings The complete crankcase must be replaced if either half is damaged e Installation is the reverse of removal O Apply fine oil to both ball bearings O Apply heat resisting grease between oil seal lips O Make sure that the dowel pins E are correctly placed onto crankcase B before assembly If the original crankcase is reused remove liquid must be cleaned thoroughly to ensure a perfect seal e Sparingly apply liquid gasket on the sealing surface of the starter half of the crankcase e Put the crankcase B and the crankcase C in between both sides of the crankshaft F so that the dowel pins E can be fitted into their holes on the crankcase C and tighten the bolts 1 2 3 to the specified torque evenly in the order shown see Tightening Torque www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 16 ENGINE Crankcase and Crankshaft Crankshaft Shim Selection Whenever any one of the crankshaft the crankcase and the ball bearing is replaced select the crankshaft shim
10. in lb Crankcase Connecting MTGS 3 4 3 9 0 35 0 40 30 4 34 7 in lb Engine Shroud MTGS 3 4 3 9 0 35 0 40 30 4 34 7 in lb Carburetor Air Cleaner Case MTGS 3 4 3 9 0 35 0 40 30 4 34 7 in lb Insulator MTGS 3 4 3 9 0 35 0 40 30 4 34 7 in lb Fuel Tank MTGS Crankcase side 3 4 3 9 0 35 0 40 30 4 34 7 in lb Fuel Tank MTGS Recoil Starter side 2 0 2 5 0 20 0 25 17 4 21 7 in lb Muffler MTGS 3 4 3 9 0 35 0 40 30 4 34 7 in lb Muffler Cover MTGS 3 4 3 9 0 35 0 40 30 4 34 7 in lb Cylinder MTGS 3 4 3 9 0 35 0 40 30 4 34 7 in lb Clutch Shoe MTGS 7 8 9 8 0 80 1 00 69 4 86 8 in lb Flywheel Nat 7 8 9 8 0 80 1 00 69 4 86 8 in lb Starter Pulley Nut 13 7 15 7 1 40 1 60 10 1 11 6 Starter Pulley 9 8 11 8 1 00 1 20 7 2 8 7 Spark Plug 11 8 16 7 1 20 1 70 8 7 12 3 in lb General Bolts and Nuts 2 5 2 9 0 25 0 30 21 7 26 0 in lb General Bolts and Nuts 3 4 3 9 0 35 0 40 30 4 34 7 in lb General Bolts and Nuts 5 9 7 8 0 60 0 80 52 1 69 4 in lb FRAME Grease Hole Bolt 3 9 4 9 0 40 0 50 34 7 43 4 in lb Gear Case Clamp Bolt 3 4 3 9 0 35 0 40 30 4 34 7 in lb Gear Case Alignment Bolt 3 4 3 9 0 35 0 40 30 4 34 7 in lb Cutter Blade Mounting Nut 14 7 18 6 1 50 1 90 10 8 13 7 Guard Clamp Bolt 3 4 3 9 0 35 0 40 30 4 34 7 in lb Guard Clamp Nut 3 4 3 9 0 35 0 40 30 4 34 7 in lb Loop Handle Socket Bolt 1 5 2 0 0 15 0 20 13 0 17 4 in lb Clutch Housing M
11. manuals and parts catalogues to tell you the details In order to perform the work efficiently and to avoid costly mistakes read the text thoroughly familiarize yourself with the procedures before 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 equipment e Follow the Periodic Maintenance Chart in their respec tive owner s 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 Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices This warning symbol identifies special instruc tions or procedures which if not correctly fol lowed could result in personal injury or loss of life CAUTION This caution symbol identifies special instruc tions or procedures which if not strictly ob served could result in damage to or destruc
12. or fire Cutter Removal e Align the lock tool hole F of the holder with the tool retaining cutout G in the gear case Then insert the Allen wrench that is supplied with the unit to prevent the cutter from turning e To loosen the nut A use a 17mm socket wrench to turn it clockwise Then remove the nut A holder B cutter blade C in that order Nut A Holder 1 B Cutter Blade C Holder 2 D Holder Flange E Lock Tool Hole F Tool Retaining Cutout G NOTE O Before replacing the old cutting blade with the new one check for and remove any debris built up in the guard Then after cleaning the inside of guard install new cutting blade Debris build up may cause the guard to crack or break with new cutting blade 327 000382 C NOTE O To protect the gear case shaft insert the top and bottom holders and temporarily tighten them with nuts Cutter Installation e Installation is the reverse of removal Torque Nut 10 mm 14 7 18 6 N m 1 5 1 9 kg m 10 8 13 7 ft Ib AWARNING Securely install the cutter blade on the holder flange and tighten the nut to the specified torque Failure to properly tighten it could cause abnormal vibration or the loosening of the nut which could lead to the cutter blade flying away NOTE O Apply a thin coat of grease to the splines of the shaft www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FRAME 2 5
13. 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 KEL26A www mymowertrparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 5 General Specifications Item Product code KEL26A HE026A AS00 Engine code THO26D AN32 Dimension Overall length Overall width Overall height Overall weight Engine Type Displacement Bore x stroke Carburetor Ignition Spark Plug Starter Clutch Air cleaner 1749 mm 68 8 in 387 mm 15 2 in 303 mm 11 9 in 5 5 kg 12 1 lb without cutter empty fuel tank TH26D Forced air cooled 2 stroke single sylinder gasoline engine 25 4 mL 1 55 cu in 34 x 28 mm 1 34 x 1 10 in Diaphragm type Solid state ignition NGK BPMR6A Recoil starter Automatic centrifugal type 54 mm 2 1 in Felt element Fuel Mixing ratio Tank capacity 50 parts of regular unleaded gasoline to 1 part of 2 stroke engine oil by volume JASO Service Classfication FC class 0 6L Frame Cutter length Cutter width Cutter thickness Main pipe Main cable Gear ratio Rotation of the cutting blade Lubrication 203 mm 8 0 in 50 8 mm 2 0 in 2 3 mm 0 09 in 24 mm 0 94 in 6 mm
14. s to adjust crankshaft axial play according to crankshaft shim selection e Measure dimension of A B and C shown in the figure and calculate crankshaft clearance dimension D by the following equation D A B C NOTE O Measure dimension of A and B at the outer race not to allow ball bearing axial play to affect the shim selection Shim Thickness mm Shim Parts No 0 2 0 008 in 92025 2125 0 4 0 016 in 92025 2126 Cc 0 6 0 024 in 92025 2127 Magneto Side Clearance dimension D mm Fitting shim 0 05 0 27 0 002 0 0106 in None 0 28 0 47 0 0110 0 0185 in 92025 2125 0 48 0 67 0 0188 0 0264 in 92025 2126 0 68 0 79 0 0268 0 0311 in 92025 2127 Crankshaft Shim Installation e Install shim s A selected onto the crankshaft as shown and assemble the crankcase Crankshaft Axial Play Standard 0 05 0 295 mm 0 002 0 0116 in thrust runout of ball bearing not included www mymowertrparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING 4 1 Troubleshooting Table of Contents Engine Troubleshooting des gaatee cee tana ii cele eee 4 2 Hard Starting causada A bt oR ee a he a 4 2 Engine Malfunction at LOW Speed ceeccscceseesseeeseeseeeseneeeneceecseeceesseesnecseessaessaecanessaecseessaeeaeseeeesaesaeseaeeeaeseaeseaeseaeees 4 4 Engine Malfunction at High Speedi piniienn a rear 4 4 Insufficient Powers201 5 d
15. the ignition lead wire A e Unscrew the fan housing mounting screws B to remove the fan housing C e Unscrew the ignition coil mounting bolts D to remove the ignition coil E together with the insulators Installation e Installation is the reverse of removal e Adjust the air gap B between the ignition coil A and flywheel C to the specified value Ignition Coil Air Gap Specified 0 3 to 0 5 mm 0 012 to 0 020 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE 3 11 Recoil Starter Shroud Fan Housing and Ignition Coil e Install the starting pulley to the crankshaft by turning clockwise Rotating Direction seen from recoil side The recoil pawl must be fitted on the pulley as shown Recoil Pawl Ignition Coil Inspection The ignition coil has been integrated with an igniter being solid state e Use the Kawasaki hand tester P N 57001 1394 resistance value may vary with individual meters e Set the Kawasaki hand tester to the specified range e Connect the test leads to the points shown and read the resistance x If the resistance is not as specified replace the ignition coil xk If the meter reads as specified the ignition coil windings probably good However if the ignition system still does not perform as it should after all other components have been checked replace the ignition coil with one known to be good Ignition Coil Specified R
16. 0 24 in 13 20 Clockwise shown the guard High quality lithium grease Specifications are subject to change without notice and may not apply to every country www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 1 6 GENERAL INFORMATION Setting Table KEL26A Setting The engine speed at which the clutch engages about 4000 rpm at 0 04 N m 0 4 kg cm 0 35 in Ib of drag torque Max engine speed rpm Different depending on matching machine Low idling speed 3000 200 rpm Ignition coil air gap 0 3 to 0 5 mm 0 012 0 020 in Ignition timing 25 B T D C 7000 rpm Spark plug gap 0 6 to 0 7 mm 0 024 0 028 in Carburetor Main jet 37 5 Gear case grease capacity about 9 1 g When Gear case is completely dry www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 7 Periodic Maintenance Chart AWARNING Accidental engine starting can cause injury Always remove the spark plug cap before servicing the engine to prevent accidental starting First Every Every Every Maintenance Daily 20h 20h 50 h 100 h Check and replenish fuel e Check for fuel leakage Check bolts nuts and screws for looseness and loss Check throttle lever operation Check engine switch operation Check guard flap and wheel condition Check cutting blade condition Clean fuel filter Clean air fi
17. Celsius DC direct current F farad s F degree s Fahrenheit ft foot feet g gram s h hour s L liter s lb m min N Pa PS psi g rpm TDC TIR pounds s meter s minute s newton s pascal s horsepower pound s per square inch revolution revolution s per minute top dead center total indicator reading volt s watt s ohm s Read OWNER S MANUAL before operating www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated exhaust emission control systems EM in compliance with applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board 1 Exhaust Emission Control System The exhaust emission control system applied to this engine consists of a carburetor and an ignition system having optimum ignition timing characteristics The carburetor has been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED Federal law and California State law prohibits the following acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any ne
18. For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 KEL26A Kawasaki Handheld Edger ervice Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Department Consumer Products amp Machinery Group Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts Kawasaki Heavy Industries Ltd 2000 First Edition 1 Oct 30 2000 K www mymowertrparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LIST OF ABBREVIATIONS A ampere s ABDC after bottom dead center AC alternating current ATDC after top dead center BBDC before bottom dead center BDC bottom dead center BTDC before top dead center C degree s
19. TGS 3 4 3 9 0 35 0 40 30 4 34 7 in lb Grip Clamp Bolt 1 5 2 0 0 15 0 20 13 0 17 4 in lb Wheel Plate Clamp Bolt 5 9 7 8 0 60 0 80 52 1 69 4 in lb Wheel Nut 2 5 2 9 0 25 0 30 21 7 26 0 in lb www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 9 Clearance Table Item Service Limit mm Remarks Cylinder bore 34 1 1 343 in Replace if over Piston to cylinder clearance 0 15 0 0059 in Replace if over Piston ring to groove clearance 0 17 0 0067 in Replace if over Piston ring end gap 0 7 0 0276 in Replace if over Piston to piston pin clearance 0 1 0 0039 in Replace if over Connecting rod big end axial play 0 5 0 0200 in Replace if over Connecting rod big end radial play 0 15 0 0059 in Replace if over Piston pin to needle bearing radial play 0 15 0 0059 in Replace if over Ball bearing axial play 0 5 0 0200 in Replace if over Crankshaft axial play 0 05 0 295 0 0020 0 0116 in Adjust if over Thrust runout of ball bearing not included www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 1 10 GENERAL INFORMATION Special Tools Drum Pusher 24 mm 57001 1440 iF ST571440ST C Outside Circlip Pliers 57001 144 Bearing Puller 57001 1467 o Inside Circlip Pliers 57001 143 CO ST571467ST C ST576001ST C ST57146XST C
20. able 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 Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them evenly in a staggered sequence This is to avoid distortion of the part and or causing gas or oil leakage Conversely when loosening the bolts nuts or screws first loosen all of them by about a quarter of a turn and then remove them Where there is a tightening sequence indication in this Service Manual the bolts nuts or screws must be tightened in the order and method indicated 3 Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench 4 Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or in
21. choking gives too rich mixture Overflow of fuel from carburetor Clogged air cleaner Remove spark plug with engine switch OFF exhaust excess fuel by pulling starter rope Check carburetor and exhaust excess fuel from cylinder Clean air cleaner and exhaust excess fuel from cylinder On removing spark plug moisture condensed on spark plug electrodes Make spark check No spark but spark appears on spark plug replaced No spark in any spark plug but spark appears when the end of high tension cord is touched to engine block Faulty fuel Faulty spark plug Faulty plug cap Mixture of water into fuel Deterioration in fuel because of poor long term storage Use of fuel other than designated Electrodes are burned and damaged to cause too wide gap Much carbon bridging electrodes gap Small foreign matter being caught between electrodes Faulty insulation of electrodes eLooseness of terminal Only for spare parts spark plug Faulty contacting at spark plug cap Change fuel Change fuel Change fuel Crrect gap or replace Clean or replace Clean Clean or replace spark plug Tighten securely Remove plug cap and connect terminal again www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING 4 3 Engine Troubleshooting Symptom Cause Remedy No Spark appears when stop Faulty stop
22. cordance with the engine revolution change as vertical motion And it works to keep a uniform pressure equivalent to the fuel surface of a float carburetor inside the metering chamber by opening and closing the needle valve 7 Fuel in the metering chamber is drawn by the negative pressure in the venturi blown out from the main nozzle 17 mixed with the air passed through the venturi and sucked into the engine When the engine stops negative pressure in the venturi becomes zero the control lever 11 is pushed up with the valve spring 12 and the needle valve 7 closes Then fuel flow stops and overflow is prevented Inlet Screen Pump Body Valve Spring Lever Pin Control Lever Gasket Main Diaphragm Air Purge Body Priming Pump Priming Pump Cover Pump Cover Screw Throttle Collar Screw Idle Adjust Screw Throttle Valve Assembly Carburetor Body O ring Main Jet Pump Gasket Pump Diaphragm Lever Pin Screw Needle Valve OANDOARWNDN NAAA O000YNXOo0OUdoAa AOoONnN 0 N are www mymowertrparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 4 SUPPLEMENT Rotary Valve Diaphragm Type Carburetor Disassembly Before disassembling clean the carburetor with a high flash point solvent so that no dirt enters the carburetor e Remove 2 throttle collar screws to remove the throttle valve assembly from the carburetor body CAUTION Do not d
23. dd Re eA as Abnormal Engine Noises SU iria e Fuel Leakage from Carburetor Excessive F el Cons mptioN sn issernida a A e a A i a a Engine Stops during Operation its 4 6 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 2 TROUBLESHOOTING Engine Troubleshooting Hard Starting Symptom Cause Remedy Pulling recoil starter handle Poor compression Wear in piston Replace would not cause sufficient Wear in piston ring Replace compression After choking and making several starting attempts it is found on removing spark plug that electrodes are still dry Insufficient fuel Stick of piston ring Wear or deformation of cylinder bore Poor tightening of cylinder and spark plug No fuel in fuel tank Clogging of dust or entry of air in fuel pipe Clogged fuel tank cap air vent and breather Foul fuel filter in fuel tank Poor opening and closing of choke valve Air entering at gasket fitted to carburetor flange Clogged carburetor needle jet or main jet Clean ring groove and replace piston ring Replace cylinder and piston ring as a set Tighten Replenish Clean Clean Clean Correct Tighten or replace gasket Clean After choking and making several starting attempts it is found on removing spark plug that electrodes are excessively wet Excess fuel Faulty choking In summer or when engine is warm full
24. esistance Resistance Between B and C Primary Winding 0 8 Q to 1 2 Q R x 129 A and C Secondary Winding 9 KQ to 15 KQ R x 1 KQ NOTE O It is unable to inspect the igniter whether it is good or bad with the Kawasaki hand tester since it was integrated with the ignition coil O Whenever you have doubt as to function of the igniter to operate try replacing the ignition coil with one known to be good www mymowerparts com KOC12ACOS1 For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 12 ENGINE Flywheel and Cylinder Flywheel and Cylinder Removal e Release the flywheel nut A counterclockwise to remove it e Remove the flywheel G out of the crankshaft by using a puller H as shown Special Tool Flywheel Puller 57001 6001 e Remove the key C from the crankshaft e Unscrew the flange bolts D to remove the cylinder E and the cylinder gasket F from the crankcase e Check to see if the pulse hole A under the inlet port B is clogged x If clogged clean Flywheel and Cylinder Installation e Installation is the reverse of removal e Use a new gasket e Set the cylinder gasket noting its profile A for scavenging ports www mymowertrparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE 3 13 Flywheel and Cylinder e Scrape the carbon deposits inside the cylinder especially slit A for decompression with a
25. he gear case against a wooden block to allow the ball bearing J to fall out of the gear case D e Remove the snap ring K out of the bevel gear C to separate the ball bearing E F from the bevel gear C 327 0008N2 C Gear Case Installation e Installation is the reverse of removal O Wash the gear case D and make sure that no cutting chips or other debris remain in the case O Face the seal of the ball bearing E towards the snap ring O To press the bevel gear C sub assembly in turn the shaft to make sure that the gears mesh properly O After the installation make sure that that the gears rotate smoothly and that the parts sound normal www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 12 FRAME Cable Cable Removal e Pull out the cable E from the main pipe A Pipe A Liner B Bushing C Bushing D Cable E Spacer F 75 Section A A BUSHING Direction figure of pressing and inserting D BUSHING total amount 327 0009N2 C Cable Installation e Installation is the reverse of removal O As a rule of thumb replace the cable when it no longer transmits its movement to the cutter blade A type of cable that is saturated with grease is used www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE 3 1 Engine Table of Contents Exploded VieW ios td adi bees e
26. heck valve and the outlet check valve in particular and make sure that they are flat and not bent x If they are bent replace them with new ones e Check the main diaphragm to see if there is any peeling damage or the aluminum plate bent If they are bent replace with new one After cleaning the pump body check to see that the control lever functions well and that no dirt is found on the inlet screen CAUTION To prevent deformation or sticking of the main check valve never apply high pressure air to the valve e Check to see that there is no deformation or damage on the check valve x If any replace it with new one e Check to see that no hole damage or abnormal hardening is present on the priming pump If present replace it with new one e Push the tip end of the control lever lightly and make sure that the lever moves smoothly x If the needle valve which opens and closes with the control lever movements is damaged on its tip or worn out due to long use replace the pump body assembly x In this case replace the pump body assembly with new one e Adjust the control lever A so as to be at the same level as the bottom B of the metering chamber as shown x If correction is necessary bend the lever lightly to be on the same surface of the metering chamber bottom or adjust the lever to be from 1 4 mm 0 055 in to 1 6 mm 0 062 in C with surface of the pump body as standard e To check funct
27. hten Inferior of pump diaphragm Replace Inferior of check valve Repair Inferior of manifold o ring Replace Poor tightening of carburetor Tighten Damaged carburetor control metering lever Replace Too low carburetor control metering lever Adjust Malfunction of carburetor control metering lever Replace Poor installation of carburetor control metering lever Correct Damaged carburetor control metering lever button Replace Poor tightening of diaphragm cover Tighten Damaged diaphragm Replace Adherence of inlet needle valve Replace Engine stops when decelrating Inferior pump diaphragm Replace Too high carburetor control metering lever Agjust Malfunction of carburetor control metering lever Replace www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 8 SUPPLEMENT Rotary Valve Diaphragm Type Carburetor Troubleshooting Symptom Cause Remedy Inlet needle valve wear Replace Foreign matter sticking of inlet needle Clean Engine does not accelrate Clogged air cleaner element Clean quick Malfunction at high speed Clogged fuel tank cap air vent Clean Foul fuel tank filter Clean Clogged fuel line Clean Air leakage in fuel line Repair Improper fuel Change Pulse leakage from pulse passage Repair Clogged pulse passage Clean Poor tightening of pump cover screw Tighten Inferior of pump diaphragm Replace
28. in iak dia cael bakin beaded daa bane wae 3 11 Flywheel and Cylinders ccoo id 3 12 Flywheel and Cylinder Removal iresten naaa an a evreesdevstindecnsecdvinne seeds 3 12 Flywheel and Cylinder Installation eeeeseesceeseeeseeeeeeeseeeseeeaeesseecseeeseeeseesseesaeeeseecseesseecseesseeeseesseesseeeeesseeseneeeeeaes 3 12 PIStOM ANG PISTON RING cveesidcetsccaceceteest cestads aaa 3 14 Piston and Piston Ring Removal c 2 4 4 60 A ceebsaeg aces neem ble An Hedge dimid Go a aA N a aa 3 14 Piston and Piston Ring Installations scn aaa aia a a AA aa oaei iiiaae iN 3 14 Grankcasesand Crank haitiana atraca 3 15 Crankcase and Crankshaft REMOVAI cccccccccscsssssscceeccceeccssessssaeeeececccesecnneauasaeseaeeeceeecneesauaasaeeeseeeesccesesseeeeeeeees 3 15 Crankcase and Crankshaft InstallatiON occcoccconononocccononenonononnononannncnononnnonnnnnnonnnnnnnnnnnnrnnnnnnnnnnnnnnnnononanannnnns 3 15 Grankshiatt Shit Selection uni a a ed 3 16 Grankshatt Shims Installation a a aa 3 16 WWwwWw mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 2 ENGINE Exploded View 327 0001W4 C T1 M5 3 4 3 9 N m 0 35 0 40 kg m 30 4 34 7 in lb T2 M6 7 8 9 8 N m 0 80 1 00 kg m 69 4 86 8 in Ib T3 M5 2 0 2 5 N m 0 20 0 25 kg m 17 4 21 7 in lb www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE 3 3 Exploded View
29. insulator gasket C onto screw ends then install the insulator on the cylinder D with the screws O Each pulse hole E must align Air Cleaner Element Cleaning e Gently tap the element to remove dust or loosen accumulated dirt e Apply low pressure compressed air as appropriate or replace the element with a new one as required e Do not wash the element CAUTION More frequent maintenance is necessary when the engine is operated in dusty condition Spark Arrester Cleaning AWARNING Hot engine parts can cause severe burns Allow engine to stop and cool before servicing spark arrester e Remove the muffler cover e Remove the spark arrester by unscrewing the screw at the exhaust pipe in the muffler e Clean deposits from the spark arrester screen by brushing it e Install the spark arrester and the muffler cover www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 10 ENGINE Recoil Starter Shroud Fan Housing and Ignition Coil Recoil Starter Removal e Remove the mounting screws A to remove the recoil starter B e Release the starting pulley lock nut A counterclockwise to remove it together with the washer B e Remove the starting pulley C by turning itself counterclockwise Ignition Coil Removal e Remove the spark plug cap A out of the spark plug e Remove the guard B e Remove the shroud C and muffler cover D e Disconnect
30. ion of the main check valve stick vinyl pipe end to the main check valve and breathe in and out from the other end x If the valve opens when breathing in and closes when breathing out the valve functions well e f any problems are found soak the valve in gasoline for about 10 minutes and repeat breathing in and out several times If no improvement shows replace the pump body with new one www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 6 SUPPLEMENT Rotary Valve Diaphragm Type Carburetor Troubleshooting Symptom Cause Remedy Engine hard to start Idle adjust screw maladjustment Adjust Foul fuel filter in fuel tank Clean Clogging in fuel passage Clean Air leakage in fuel passage Repair Improper fuel Change Inferior check valve Replace Clogged air cleaner element Clean or replace Damaged carburetor control metering lever Repair Malfunction of carburetor control metering lever Repair Inferior main diaphragm gasket Replace Poor tightening of main diaphragm cover screw Tighten Damaged main diaphragm Replace Adherence of inlet needle valve Replace Inlet needle valve wear Replace Inlet needle valve sticking Repair Overflow fuel leakage Poor tightening of fuel pump cover screw Tighten Damaged carburetor control metering lever Repair Too high carburetor control metering lever Adjust Malfunction of carburetor contro
31. is the reverse of removal e Fix the fuel filter to the delivery side opaque tube and clamp it e Put the opaque tube into the fuel tank together with the fuel filter and fit the tank grommet into its hole in order that the raised letters on the tank grommet can look toward outside NOTE O Apply a bit of 2 stroke engine oil to the grommet in order to make the insertion easy e Install the tank grommet A to the fuel tank so that the transparent tube B comes toward the fuel tank center www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE 3 7 Clutch and Fuel Tank Clutch Installation e Apply locking agent to screw threads of the clutch pins e Apply a bit of heat resisting grease to the clutch pin holes e Put the clutch shoes and the plate on the flywheel with raised letter such as R54 toward you Install them by tightening the clutch pins to the specified torque Specified Clutch Pin Tightening Torque 8 10 N m 0 8 1 0 kg m 71 89 in Ib e Install the clutch spring to the clutch shoes before installing the clutch shoes on the flywheel if the clutch spring is removed Fuel Filter Cleaning e Remove the fuel filter assembly together with the grommet A from the fuel tank B to keep dust from entering the fuel filter C e Clean the fuel filter in a bath of high flash point solvent e Dry the fuel filter before installing NOTE O If fuel does not flow better w
32. isassemble the throttle valve assembly e Remove 4 pump cover screws with the priming pump side upward e Remove the priming pump cover the priming pump the air purge body the main diaphragm the gasket the pump body the pump diaphragm and the pump gasket in that order e Remove the main jet and the O ring from the carburetor body CAUTION Do not remove the main nozzle as it is press fitted If much dirt is found inside the carburetor especially on the inlet screen clean the fuel tank inside and replace the fuel filter Reassembly Before reassembly clean removed parts and the body with suitable detergent and use compressed air to dry e Reassembly is the reverse of removal www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 SUPPLEMENT 5 5 Rotary Valve Diaphragm Type Carburetor Inspection and Adjustment e Clean the carburetor with a high flash point solvent and apply air e Check to see that no dirt or corrosion is found in the main jet If dirt is found clean and apply air If corrosion is found replace the main jet with new one CAUTION When replacing the main jet be sure to replace with a jet with the same number e As to the gaskets check to see if no deformation or damage is found If deformation or damage is found replace them with new ones e Check the pump diaphram to see if no damage or hardening is found Check the inlet c
33. ith the fuel filter cleaned replace the fuel filter with a new one www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 8 ENGINE Air Cleaner Carburetor and Muffler Shroud and Muffler Cover Removal e Pull out the plug cap A e Remove the guard B e Unscrew the muffler cover screw F to remove the muffler cover E e Unscrew the shroud mounting screws C to remove the shroud D Air Cleaner Removal e Unscrew the air cleaner mounting screws A to remove the air filter cap B Carburetor Removal e Unscrew the two carburetor mounting screws A to remove the carburetor B together with the gasket NOTE O Do not remove the carburetor if not needed e Unscrew the two insulator mounting screws A to remove the insulator B together with the gasket C Muffler Removal e Unscrew the two flange bolts A to remove the muffler body complete B together with the gasket C NOTE O In ordinary circumstances there is no need to remove the muffler body complete out of the cylinder www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE 3 9 Air Cleaner Carburetor and Muffler Air Cleaner Carburetor and Muffler Installation e Installation is the reverse of removal e Use new gaskets x If the insulator A is removed fit the screw to round seat and nuts B to the hexagonal seats in the insulator and put the
34. l metering lever Repair Deformed carburetor control metering lever spring Replace Inferior main diaphragm gasket Replace Poor tightening of main diaphragm cover screw Tighten Damaged main diaphragm Replace Inlet needle valve wear Replace Inlet needle valve sticking Repair Priming is hard to suck fuel Clogged fuel tank cap air vent Clean Foul fuel filter in fuel tank Clean Clogged fuel line Clean Air leakage in fuel line Repair Damaged priming pump Replace Inferior priming pump check valve Replace Malfunction of carburetor control metering lever Repair Inferior main diaphragm gasket Replace Poor tightening of main diaphragm cover screw Tighten Damaged main diaphragm Replace Adherence of inlet needle valve Replace Engine would not idle Idle adjust screw maladjustment eAdjust Foul fuel filter in fuel tank Clean Air leakage in fuel line Repair Inferior manifold o ring Replace Poor tightening of carburetor Tighten Idling is too slow Clogged air cleaner element Clean or replace Damaged carburetor control metering lever Replace Carburetor control metering lever is too high Adjust Malfunction of carburetor control metering lever Replace Inlet needle valve wear Replace Foreign matter sticking of needle valve Clean www mymowertrparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 SUPPLEMENT 5 7 Rotary Valve Diaphragm Type Carbu
35. led spark appears very Faulty magneto Replace week Faulty ignition coil Engine Malfunction at High Speed Symptom Cause Remedy Same as Engine Malfunction at Low Speed mentioned above Faulty carburetor Faulty fuel filter Faulty ignition Same as Engine Malfunction at Low Speed Same as Engine Malfunction at Low Speed system Loaded operation causes Clogged fuel tank cap air vent and breather Clean revolution fluctuation with big Dust clogging in or entry of air into fuel pipe or Clean frequency carburetor Insufficient Power Symptom Cause Remedy Same as Hard Starting Poor compression Insufficient fuel Excess fuel Faulty fuel Faulty magneto Faulty igniter Same as Hard Starting Same as Hard Starting Engine overheated Clogged air cleaner Carbon deposit inside combustion chamber Inappropriate mixing ratio too little oil Broken cooling fan blade Dirt or dust attached to cooling fins of cylinder Grass or dirt attached to cooling air passage and flywheel blade Clean Clean Change fuel Replace Clean Clean Thick smoke issues from Excess fuel Same as Hard Starting Same as Hard Starting exhaust port Faulty exhaust system eCarbon deposit narrows exhaust passage and muffler Excessive oil mixed Clean Change fuel Engine knocking Inferior fuel Change fuel www my
36. lter element Tighten bolts nuts and screws Clean spark plug and adjust electrode gap Remove dust and dirt from cylinder fins Check gear case assembly lubrication K Check drive cable lubrication Clean net of spark arrester Remove carbon deposits in the exhaust pipe of muffler K Remove carbon deposits on piston head and inside cylinder K Check the sliding portion of crankshaft connecting rod etc Fuel tube It is recommended to replace every 3 years NOTE O The service intervals indicated are to be used as a guide Service to be performed more frequently as necessary by operating condition K These items must be performed with proper tools See your authorized Kawasaki dealer for service www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 1 8 GENERAL INFORMATION Tightening Torque The following tables list the tightening torque for the major fasteners and the parts requiring use of a non permanent locking agent or requid gasket Letters used in the following Tightening Torque table mean MTGS Mounting screw s LA Apply a non permanent locking agent to the threads LG Appy a liquid gasket to the sealing surfaces Tightening Torque KEL26A Fastener Remarks Engine Air Cleaner Cap MTGS 2 0 2 5 0 20 0 25 17 4 21 7 in lb Ignition Coil MTGS 2 0 2 5 0 20 0 25 17 4 21 7 in lb Recoil Starter MTGS 1 7 2 0 0 17 0 20 14 8 17 4
37. ming pump check valve During priming pump operation the valve functions as both inlet and outlet check valves Overflow pipe Air outlet from carburetor to tank Air from carburetor is forced out through this passage when primer bulb is compressed Idle adjust screw Engine idling speed is adjusted Function 1 Priming pump system When starting the engine by pushing or pinching the priming pump 18 air is pushed out toward the overflow pipe 21 from the priming pump check valve 20 which causes negative pressure inside the metering chamber 13 and the needle valve 7 opens Then fuel from the fuel tank is sucked into the metering chamber through the inlet check valve 4 and then into the priming pump And excessive fuel is discharged from the overflow pipe This operation is called Priming operation at starting Fuel pump system After starting the engine part of the pressure change inside the crankcase caused by engine revolution is transmitted to the pump diaphragm 2 through the engine pulse passage 1 which deforms the pump diaphragm and it starts reciprocating motion Namely fuel is sucked from the tank into the carburetor under pressure by the volume change due to the pump diaphragm s reciprocating motion and the inlet 4 and outlet check valves 5 function Metering chamber system The main diaphragm 10 forming the metering chamber senses the inside fuel pressure change of the metering chamber 13 which occurs in ac
38. mowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING 4 5 Engine Troubleshooting Abnormal Engine Noises Symptom Cause Remedy Piston Slapping Cylinder and piston ring wear Replace Wear and or deformation in piston Replace eCarbon deposit inside combustion chamber Clean Wear in piston pin and connecting rod small end Replace bearing Wear in piston and piston pin Replace Connecting rod noise Wear in large and small end bearings Replace Crankshaft Assy Surging Symptom Cause Remedy Surging Foul air cleaner Clean Dust clogging in or air entry into fuel pipe Clean Clogged fuel tank cap air vent and breather Clean Clogged carburetor Clean Fuel Leakage from Carburetor Remedy Fuel leak from carburetor Foreign matter attached to needle valve and or valve Clean seat Correction or wear in needle valve and or valve seat Replace needle valve assembly Poor tightening of diaphragm gasket Tighten or replace Excessive Fuel Consumption Symptom Cause Remedy Same as Hard Starting Poor compression Same as Hard Starting Same as Hard Starting Sufficient compression but Too rich fuel mixture Adjust excessive fuel consumption Inferior fuel Replace Foul air cleaner Clean Too high idling speed Adjust Choke valve not fully open eAdjust Same as Fuel Leakage Same as Fuel Leakage from Same as Fuel fr
39. nnnrnnnnnnennnnnnns 2 9 Wheel and Attached Parts InstallatiON cccoooncononocacocanonenonanonoanoonnnnnonononnnnnnnnnnnnnnnonnncnnnnnnnnnrnnnnnnnnnnnrnnnnnnnnnrnnnnnos 2 9 NE ao a AT 2 10 Guard Removal uan is A aan hs 2 10 Gear Case and Attached Parts InstallatiON cooccnccnnocccccnonoconcnnanannnonnnrnnnnononononcnnnononcnnnonnnnononnnnnnnnnnnnnnnnnnnnnncns 2 10 Gear Caserta an RA n 2 11 Gear Case Disassembly pissin eaea an aeaa dad edit ea 2 11 Gear EEE EO A EE a AA Aa Aaa A CDi 2 11 GA e ataco 2 12 Cable REMOVAL nia A dE reis 2 12 Cable asta ic adas asc 2 12 WWwwWw mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 2 FRAME Exploded View T1 M10 14 7 18 6 N m 1 50 1 90 kg m 10 8 13 7 ft lb T2 M6 3 9 4 9 N m 0 40 0 50 kg m 34 7 43 4 in Ib T3 M5 3 4 3 9 N m 0 35 0 40 kg m 30 4 34 7 in lb T4 M8 2 5 2 9 N m 0 25 0 30 kg m 21 7 26 0 in lb T5 M6 5 9 7 8 N m 0 60 0 80 kg m 52 1 69 4 in Ib www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FRAME 2 3 Exploded View T1 M5 1 5 2 0 N m 0 15 0 20 kg m 13 0 17 4 in lb www mymowertrparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 4 FRAME Cutter ADE Stop the engine and completely drain the fuel tank before disassembling the unit Pay close attention to prevent burns
40. om Carburetor Carburetor Leakage from Carburetor www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 6 TROUBLESHOOTING Engine Troubleshooting Engine Stops during Operation Symptom Difficulty in cranking or Overheat seizure Cause Excessively lean fuel mixture too little fuel Inferior lubricating oil mixed Excessive carbon deposit in conbusion chamber Dust accumulation on cooling fins of cylinder Remedy Adjust carburetor Change fuel Clean Clean Cranking is easy Faulty electrical system Faulty fuel system Faulty spark plug Faulty magneto Looseness in connections Faulty ignition coil Clogged fuel line Foul air cleaner Fuel in tank used up Clean or replace Replace Check and repair Replace Clean Clean or replace Replenish Faulty carburetor Dust clogging in fuel passage Clean www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 SUPPLEMENT 5 1 Table of Contents Rotary Valve Diaphragm Type Carburetor cccccccecccceeeceeeeceeeceeeeeaeeeceaeeceaeeeeaeeecnaeescaeeesaeeseaeeesaeeseaeeeseaeeseaeesseeeeseaeeeee 5 2 Disassembly rocne naa dani ani a a ra hulu he a een le ihe a a a N a 5 4 Reassembly it AE et cd a 5 4 Inspection anA AUS MN iia ad 5 5 Rotary Valve Diaphragm Type Carburetor Troubleshooting oomicinionionnnnnonenn
41. pe D Complete Gear Case Guard and Wheel Installation e Installation is the reverse of removal Torque Clamp Bolt 5 mm 3 4 3 9 N m 0 35 0 40 kg m 30 4 34 7 in Ib Alignment Bolt 5 mm 3 4 3 9 N m 0 35 0 40 kg m 30 4 34 7 in Ib O Pull out the cable B from the main pipe A and insert the cable opening into the pinion hole in the gear case O Insert the gear case C so that it comes in contact with the end face of the main pipe then align the alignment bolt D with the locating hole E of the main pipe and tighten it www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FRAME 2 9 Wheel and attached Parts Wheel and Attached Parts Removal e Remove the wheel nut A spring washer B and washer C then remove the wheel D and collar E e Remove the three bolts B that retain the plate A from the guard C then remove the plate A together with the long bolt D Wheel and Attached Parts Installation e Installation is the reverse of removal Torque Wheel Nut 8 mm 2 5 2 9 N m 0 25 0 30 kg m 21 7 26 0 in Ib Plate Bolts 6 mm 5 9 7 8 N m 0 60 0 80 kg m 52 1 69 4 in Ib O After installing the wheel make sure that the wheel moves smoothly up and down and secure it in place O Secure the wheel at its topmost position www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 10 FRAME Guard
42. retor Troubleshooting Symptom Cause Remedy Idling is unstable Idle adjust screw maladjustment Agjust Clogged fuel tank cap air vent Clean Foul fuel filter in fuel tank Clean Clogged fuel line Clean Air leakage in fuel line Repair Improper fuel Change Inferior check valve foreign matter Replace Inferior manifold o ring Replace Poor tightening of carburetor Tighten Malfunction of carburetor control metering lever Replace Poor installation of carburetor control lever Correct Damaged main diaphragm Replace Adherence of inlet needle valve Replace Foreign matter sticking of needle valve Clean Idling does not continue eldling adjust screw maladjustment Adjust Foul fuel tank filter Clean Clogged fuel line Clean Air leakage in fuel line Repair Inferior check valve foreign matter Replace Too high carburetor control metering lever Adjust Malfunction of carburetor control metering lever Replace Deformation of carburetor control matering lever spring Replace Poor installation of carburetor control lever spring Correct Inlet needle valve wear Replace Foreign matter sucking of inlet needle Clean Engine does not accelerate Clogged fuel tank cap air vent Clean Foul fuel tank filter Clean Clogged fuel line Clean Air leakage in fuel line Repair Pulse leakage from fuel pump Repair Clogged pulse passage Clean Poor tightening of pump cover screw Tig
43. rnrcnrcnrcnnrcnrcnrrnrnrrnr inn 5 6 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 2 SUPPLEMENT Rotary Valve Diaphragm Type Carburetor Internal Construction ff r OT Y WAS ANNAN XS N LS N y N ES A LA N N ANK SR Gasoline i N 0000000000 A N y rca DA Na SS Crank Pulse 2200560 000G 327 0013W2 C a Engine pulse passage Pressure change Inside the crankcase goes through this passage and the fuel pump diaphragm moves 2 Fuel pump diaphragm The fuel pump diaphragm waves corresponding to engine pulse which supplies fuel to the metering chamber 3 Fuel inlet Fuel inlet from the fuel tank 4 Inlet check valve Corresponding to the movement of the pump diaphragm the valve opens when negative pressure acts on the diaphragm and closes when positive pressure acts on it Outlet check valve Being very reverse to the inlet check valve the valve closes when negative pressure acts on the diaphragm and opens when positive pressure acts on it Inlet screen Prevention of penetration of dirt in fuel 7 Needle valve Linked with the main diaphragm the valve controls fuel flow supplied to the metering chamber 8 Throttle valve The throttle valve controls the air fuel mixture supplied to the engine and controls engine output 9 Air vent air hole To make the diaphragm movement smoo
44. stall 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 5 Edges Watch for sharp edges especially during major engine disassembly and assembly Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over 6 High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent commonly available in North America is Standard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent 7 Gasket O Ring Do not reuse a gasket or O ring once it has been in service The mating surfaces around the gasket should be free of foreign maker and perfectly smooth to avoid oil or compression leaks 8 Liquid Gasket Non Permanent Locking Agent Follow manufacturer s directions for cleaning and preparing surfaces where these compounds will be used Apply sparingly Excessive amounts may block engine oil passages and cause serious damage An example of a nonpermanent locking agent commonly available in North America is Loctite Lock n Seal Blue 9 Press A part installed using a press or driver such as a journal should first be coated with oil on its outer or inner circumference so that it will go into place smoo
45. suitable tool www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 14 ENGINE Piston and Piston Ring Piston and Piston Ring Removal CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Remove snap rings A out of the piston B e Pull the piston pin C off the piston B to remove the piston B and the needle bearing D out of small end of the connecting rod E e Remove piston rings F out of the piston B Piston and Piston Ring Installation e Installation is the reverse of removal B e Position the piston rings A in order that the radii at the ring gap can meet at the piston ring stopper pin B in the piston groove when the rings are compressed Z TZ A e Fit the needle bearing into small end of the connecting rod to install the piston to small end of the connecting rod with the mark A on piston crown pointing to specified side with the piston pin O H mark A on piston crown should face muffler side www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE 3 15 Crankcase and Crankshaft Crankcase and Crankshaft Removal e Unscrew the tightening screws A to split the crankcase B from the crankcase C O Lightly tap the crankcase with a plastic hammer to split apart both crankcases from the crankshaft F
46. switch Stop switch lead wire is Correct spark switch wire is jammed or disconnected at Short circuit in stop switch Replace very connector week No spark appears even Slow recoil starter Recoil starter revolution is Pull recoil starter rope spark when stop switch wire is revolution lower than that igniter begins to more rapidly at the disconnected at work end connector of Spark appears when Faulty ignition coil Wiring of coil coming short Replace high ignition coil is replaced circuited or disconnect ten with new one Stop lead wire is jammed Correct or replace Spark appears when Faulty flywheel Flywheel demagnetized Replace flywheel is replaced with new one www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 4 TROUBLESHOOTING Engine Troubleshooting Engine Malfunction at Low Speed Symptom Cause Remedy When throttle valve is opened Faulty carburetor Clogging in carburetor inside Disassemble and clean gradually revolution speed Faulty fuel filter Foul fuel filter Clean or replace drops at some position or Air enters at Faulty carburetor gasket Replace engine stops carburetor gaskets Incomplete fitting of carburetor Tighten and or insulator When spark test of spark plug Faulty ignition Faulty insulation of spark plug Replace is made with recoil starter rope system Foul electrodes Clean pul
47. th the hole is exposed to the atmosphere 10 Main diaphragm Moving up and down by the differential pressure between the engine vacuum and the atmospheric pressure the main diaphragm transmits the movement to the control lever and controls the needle valve operation and fuel flow 11 Control lever The control lever transmits the movement of the main diaphragm to the needle valve and gets the valve to open and close 12 Valve spring The valve spring continually functions in the direction which closes the needle valve and controls the movement of the control lever so that a uniform negative pressure is kept inside the metering chamber 13 Metering chamber Fuel reservoir to supply fuel to the nozzle 14 Lead cam As the throttle valve opens inlet air increases The lead cam moves the idle needle or idle needle pin up and down so as to supply proper fuel flow for the increased air 15 Main Jet Fuel at high speed is controlled al o www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 SUPPLEMENT 5 3 Rotary Valve Diaphragm Type Carburetor 16 17 18 19 20 21 Main nozzle Fuel flow is controlled by a triangle shape outlet area for idle and partial speed Priming pump Pushed repeatedly by hand the pump sucks fuel into the metering chamber from the fuel tank Main check valve During priming pump operation the valve prevents air from entering the metering chamber through the nozzle Pri
48. thly 10 Ball Bearing When installing a ball bearing the bearing race which is affected by friction should be pushed by a suitable driver This prevents severe stress on the balls and races and prevents races and balls from being dented Press a ball bearing until it stops at the stop in the hole or on the shaft 11 Oil Seal Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally damages seals When pressing in a seal which has manufacturer s marks press it in with the marks facing out Seals should be pressed into place using a suitable driver which contacts evenly with the side of seal until the face of the seal is even with the end of the hole 12 Seal Guide A seal guide is 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 13 Circlip Retaining Ring Replace any circlips and retaining rings that were removed with new ones as removal weakens and deforms them When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more 14 Cotter Pin Replace any cotter pins that were removed with new ones as removal deforms and breaks them www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 3
49. tion of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of information NOTE O This note symbol indicates points of particular in terest for more efficient and convenient operation e Indicates a procedural step or work to be done O Indicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a WARNING CAUTION or NOTE Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub step it follows www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 1 General Information Table of Contents Before Servicing ii Stacie Hoel ain eles eed een ween A a A ee 1 2 Model Identification isea ssaiatadnas es e ia 1 4 General Specifications aissei i A A A iO 1 5 Setting Table outra ist ta 1 6 Periodic Maintenance Chati Rat 1 7 Tightening TOrqU Eisenia oae aea ana aaa e ea eaa oddvamacehaveusyenet hacen a vai id aus ceases aagi 1 8 Clearance Table ia A Ae A a d 1 9 Special Toolsti ad her el ASA an Ae eB ee a ae Na ade al i a Seth Se eh Bebheehd 1 10 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 applic
50. um 3 2 Housing Clutch Drum and Dampe sisisi ianiai a ec 3 4 Housing REMOVval i e ikia a aaraa reaa AEEA a ies 3 4 GlutehDrtim Removal iii dida ic 3 4 Clutch Drum INSTAlatiON ia a NA 3 4 Damper RM ii A A A A ti 3 5 Installation a atada ia 3 5 Clutch and Fuel Tank ccccccccccssssssssecceecceceecssessssseeeeceecceeecsnsesuuuaeeeeaseceeecenseaaaaeeeeeaeseececeneesaauseaeeeaeeceseeeseesaaseeeeeeeeeeeeee 3 6 cltich Removal Lai ts e e lead ee ato etl A ente eee des ela de ot E 3 6 FuelTank Removals madai dt laa a oa 3 6 Fuel Tank Installation dia tos 3 6 Clutchinstalai e o E O A 3 7 Fuel Filter Cleaning meian A redo eee 3 7 Air Cleaner Carburetor and Mf ET a a a a aa a 3 8 Shro d andi Muffler Cover Removal ui a A E T A araara 3 8 Air Cleaner Ren E A A A RRR RENAN 3 8 Carburetor R MoA a ea e E aliada cid 3 8 Muffler Rem OVA ici a a a a a EA a 3 8 Air Cleaner Carburetor and Muffler Installation c c cccccccccccccsssessnsceeeeeseececesesesaaaeeeeeeeeeesseseesesaeeeaeeeeeeesseeeseeaes 3 9 Air Cl an r Element Cleanings iio E a a a a a aai 3 9 Spark Arrester Gleanings sii hinsti aiana a le 3 9 Recoil Starter Shroud Fan Housing and Ignition Coil ccccccecceceeseecesceeeeeeeeneeceaeeeeeeeeeeaeeceaeeeseaeeseaeessaeeeeseeeseneeteaees 3 10 RecollStarter Remova atendida datada ala 3 10 Ignition Coil Removals sienna ate AA seen OEA 3 10 Instala a o UM bE E A E ne Sache ae 3 10 Ignition Coil Inspection svi
51. w engine for the purpose of emission control prior to its sale or deliverly 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 consituite tampering are the acts listed below Do not tamper with the original emission related part e Carburetor and internal parts e Spark plugs e Magneto or electronic ignition system e Fuel filter e Air cleaner elements www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it con tains enough detail and information to make it useful to the owner who desires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily Whenever the owner has insufficient expe rience or has doubts as to his ability to do the work all adjustments maintenance and repair should be carried out only by qualified mechanics This manual cover model KEL26A HE0O26A AS00 As for safety information specifications exploded view assembly and preparation operating instructions and periodic maintenance this manual does not mention them as you can depend upon their respective owner s

KEL26A Handheld Edger Service Manual

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