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1. 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 Environ mental Protection Agency and California Air Resources Board 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 new engine for the purpose of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the engine after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Do not tamper with the original emission related part e Carbu
2. e Set the reel onto the center shaft of the case C so that the hook A inside the recoil spring securely catches on the tab B of the reel CAUTION Be careful that the recoil spring may fly out and cause injury The spring is under great pressure e Pass the rope end through the rope guide from the inside of the case After threading rope through grip make a knot at the rope end and push the knot into the hole of grip e Install the damper spring B into the reel A e Fit the projection A of the damper spring into the hole B of the cam plate C and set the cam plate onto the reel e Tighten the recoil starter set screw A Torque Recoil Starter Set Screw 3 4 N m 0 35 kgf m 30 in Ib e First align the notch A with the rope guide B e Holding the reel with hand rotate the reel another five turns with the rope inserted into the notch on the outside of reel in the counterclockwise C e While holding the reel to keep it from unwinding out of the rope from the notch of the reel www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 8 RECOIL STARTER Kar Recoil Starter e While carefully holding the starter case A and starter grip B draw out the rope through the starter case and return it slowly e Check if the reel operates smoothly by pulling the rope www mymowerparts com For Kawasaki Discount Parts Call 606 678
3. 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 Service Data Service Data terms are defined as follows Standards show dimensions or performances which brand new parts or systems have Service Limits indicate the usable limits If the measurement shows excessive wear or dete riorated 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 www mymowerparts COM For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 5 General Specifications Piston Displacement 26 3 mL 1 60 cu in Clutch Type Automatic centrifugal type Clutch Drum Bore 054 Carburetor Diaphragm with starter button type TZ11K 2A by TK Air Cleaner Dry type Dimensions Lx WxH 167 mm x 217 mm x 231 mm 6 57 in x 8 54 in x 9 09 in Dry Weight 2 3 kg 5 1 Ibs Mixing Ratio Regular unleaded gasoline 50 1 2 stroke engine oil JASO FC class Tank Capacity 0 6 L 0 63 US qt Specifications subject to change without notice 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 Perio
4. Press the spring with thumb work with care so that spring will not fly e When removing the recoil spring press the spring with thumb to remove it from the case in the way like freeing the spring from winding gradually from the center of the coil to outer side www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 6 RECOIL STARTER Kar Recoil Starter Recoil Starter Assembly A WARNING In removing and installing the recoil spring protect your hands with gloves The recoil spring that flies loose can injure your Press the spring with thumb work with care so that spring will not fly e When reinstalling the removed recoil spring first wind it to make its outer diameter smaller than the inner diameter of the case and tie it with fine wire A as shown Then put the spring with its outer end hooked in the case e Apply a grease to the center shaft A of the case and the recoil spring B e Pass the rope end through the rope guide C from the outside of the case e Pass the rope end through the reel hole D as shown e Make a knot E at the rope end e Wind the rope onto the reel two and half turns and insert the rope end into the notch B on the out side of reel as shown Taking care not to reverse the winding direction A www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 RECOIL STARTER 7 7 Kar Recoil Starter
5. monly 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 matter 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 non permanent 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 smoothly 10 Ball Bearing Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary Replace any ball or needle bearings that were removed with new ones Install bearings with the manufacturer and size marks facing out applying pressure evenly with a suitable driver to the end of the race that contacts the press fit portion and press it evenly over the base component 11 Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally dam ages seals When pressing in a seal which has manufa
6. tenance chapter Fuel Leakage Inspection e Refer to the Fuel Leakage Inspection in Periodic Mainte nance chapter www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 15 Air Cleaner Air Cleaner Element Inspection and Cleaning e Refer to the Air Cleaner Element Inspection and Cleaning in Periodic Maintenance chapter Air Cleaner Removal e Pushing down the hook remove the air cleaner cap A e Remove the air cleaner element A e Unscrew the carburetor mounting screws B to remove the air cleaner case C e Check to see that no dirt is found in the air cleaner case x lf dirt is found clean it NOTE ODo not remove the carburetor if not needed Air Cleaner Installation e Install the air cleaner case and tighten with the screws Torque Carburetor Mounting Screws 3 7 N m 0 38 kgf m 2 7 in Ib e Install the air cleaner element and air cleaner cap www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 4 1 Engine Top End Table of Contents sy dellelel sel ER EA AR OE ER N 4 2 Speciflcations EE EE OE OT 4 4 Gylitidet PIS ODE ses iod tote Ge gese AE needs reete suf ali ilar ace tarte o Eat AE ee tede onde AE 4 5 Cylinder sine T 4 5 Cylinder Installationen D 4 5 Cylinder Fins Cle
7. 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 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 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 com
8. 561 4983 3 4 FUEL SYSTEM Specifications Item Standard Carburetor Make type TK TZ11K 2A Main Jet MJ 40 Idling Speed Idling speed 3 000 200 r min rpm Air Cleaner Type Dry type Idling speeds may vary depending on each mounting equipment Refer to the mounting equipment specification www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 5 Carburetor Idling Speed Adjustment e Refer to the Idling Speed Adjustment in Periodic Mainte nance chapter Carburetor Removal e Remove Air Cleaner Cap see Air Cleaner Removal in this chap ter Air Cleaner Element see Air Cleaner Removal in this chapter e Remove the fuel tubes from the carburetor see Fuel Tank Removal in this chapter e Unscrew the carburetor mounting screws A and remove the air cleaner case B and gasket C together with the carburetor D NOTE ODo not remove the carburetor if not needed e Remove the engine shroud A see Cylinder Removal in Engine Top chapter e Unscrew the insulator mounting screws B and remove the gasket and plate C together with the insulator D and gasket Carburetor Installation e If the insulator A is removed apply a non permanent locking agent to the mounting screws and fit the screw to round seat and nuts B to the hexagonal seats in the insulator e Put the new insulator gasket C and plate F to the nut side of
9. 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 2003 Kawasaki Heavy Industries Ltd First Edition 1 July 17 2003 K www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LIST OF ABBREVIATIONS ABDC AC ATDC BBDC BDC BTDC ampere s after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree s Celsius direct current farad s degree s Fahrenheit foot feet gram s hour s liter s Ib m min N Pa PS psi r rpm TDC TIR i xe 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
10. Jet 7 Pulse Chamber 20 Throttle Valve 8 Needle Valve 21 Jet Needle 9 Main Diaghragm 22 Starter Button 10 Control Lever 23 Idle Adjust Screw 11 Control Lever Spring 24 Cable Adjuster 12 Metering Chamber 25 Throttle Lever 13 Air Vent Function of each Portion 1 Fuel inlet port Fuel inlet from the fuel tank 2 Filter Prevention of penetration of dirt in fuel 3 Pump diaphragm Pump diaphragm is actuated by the engine pulse that is the alternating positive negative pressure in crank case which is caused by the reciprocating motion of piston in engine and by this operation fuel is sucked through fuel inlet and fed under pressure to needle valve 4 Inlet check valve This valve set ata part of pump diaphragm works with operation ofthe pump diaphragm and opens for only fuel flow into pump chamber 5 Outlet check valve This valve set at a part of pump diaphragm also works with operation of the pump diaphragm but opens for only fuel delivery from pump chamber 6 Pump chamber This chamberis formed between the pump diaphragm and pump cover and volume ofthe chamber is increased and decreased by operation of pump diaphragm Fuel enters the chamber as the chamber volume increases and drains from the chamber as the volume decreases www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 7 Carburetor 7 Pulse chamber This chamber is formed between pump diaphragm and a part of the ca
11. Parts Call 606 678 9623 or 606 561 4983 8 4 TROUBLESHOOTING Engine Troubleshooting Symptom Cause Remedy No spark or Spark appears when Faulty engine e Engine switch lead wire e Correct very week engine switch lead switch is jammed spark at the wire is disconnected end of high at connectors tension on cord No spark appears Slow recoil e Recoil starter revolution e Pull recoil starter even when stop starter is lower than that igniter rope more rapidly switch wire is revolution begins to work disconnected at e Short circuit in engine e Replace switch connectors Spark appears Faulty ignition e Wiring of coil coming e Replace when ignition coil coil short circuited or e Correct or replace is replaced with a disconnect new one e Engine switch lead wire is jammed Spark appears when Faulty flywheel e Flywheel demagnetized e Replace flywheel is replaced with a new one www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING 8 5 Engine Troubleshooting Engine Malfunction Symptom Cause Remedy When throttle valve is opened gradually revolution speed drops at some position or engine stops When spark test of spark plug is made with recoil starter rope pulled spark appears very week e Faulty carburetor e e Faulty fuel filter Foul fuel filter e Air enters at carburetor flange e Faulty carbu
12. SR ER Eg 6 10 sparkPlug Installation EER EE EE ee dd 6 10 Spark Plug Cleaning and lrispeeliOr tisie ks RES sd Ee SA RS de ek ka Ds Sed ui ede Bose DEEG 6 10 Spark Plug Gap Inspection oooccccccccnccnnncnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnneninnnss 6 10 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 2 ELECTRICAL SYSTEM Exploded View www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 6 3 Exploded View J e ae a Nm kem mib Ignition Coil Mounting Bolts 1 6 in lb O Apply engine oil www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 4 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Ignition System Spark Plug NGK BPMR6A Plug Gap 0 6 0 7 mm 0 024 0 028 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 6 5 Special Tools Hand Tester Flywheel Puller 57001 1394 57001 6002 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 6 ELECTRICAL SYSTEM Ignition System Ignition Coil Removal e Remove Recoil Starter see Recoil Starter Removal in Recoil Starter chapter Engine Shroud see Cylinder Removal in Engine Top chapter Fuel Tank see Fuel Tank Removal in Fuel System chap ter Air C
13. bearing into small end of the connecting rod and install the piston to small end of the connecting rod together with piston pin O J mark A on the piston crown should face the muffler side e Install the new snap rings into the piston Piston Cleaning e Refer to the Piston Cleaning in Periodic Maintenance chapter www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 8 ENGINE TOP END Muffler Muffler Removal e Remove the engine shroud see Cylinder Removal in this chapter e Unscrew the muffler mounting bolts A and remove the muffler C together with the gasket B NOTE Oln ordinary circumstances there is no need to remove the muffler out of the cylinder Muffler Installation e Apply a non permanent locking agent to the mounting Screws e Replace the gasket with a new one and install the muffler together with the gasket Torque Muffler Mounting Bolts 3 7 N m 0 38 kgf m 2 7 in Ib Muffler Cleaning e Refer to the Muffler Cleaning in Periodic Maintenance chapter www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CRANKSHAFT 5 1 Crankshaft Table of Contents Exploded RO EE N OE RE de tea bts SPECI CALONS 2s AA A EE N Sala tia eme OO ER OE EE N RE tnc oie er EA AE EO EE Rin AE OE eimi eto Grankcase Disassembly EER EER SS GE bee la edad adopt eb nga Ee ge De Ge Ro De Re EE Crankcase Assembly 2h nesses ese te SE KEN Ge
14. fuel from the fuel tank is sucked into the metering chamber through the inlet check valve and then into the priming pump And excessive fuel is discharged from the overflow pipe This operation is called Priming operation at starting Starter System This carburetor has a starter button instead of choke lever The quantity of air and fuel increases by pushing the starter button after the priming operation As a result it becomes easy to start the engine Fuel Pump System After starting the engine part of pressure change inside the crankcase caused by engine revolution is transmitted to the pump diaphragm through the engine pulse passage which deforms the pump diaphragm and it starts reciprocating motion Namely fuel is sucked from the tank into the carburetor under pressure by volume change due to the pump diaphragm s reciprocating motion and the inlet and the outlet check valves function Metering Chamber System The main diaphragm forming the metering chamber senses inside fuel pressure change of the me tering chamber which occurs in accordance with the engine revolution change as vertical motion And it works to keep a uniform pressure equivalent to the fuel surface of a float type carburetor in side the metering chamber by opening and closing the needle valve Fuel in the metering chamber is drawn by the negative pressure in the venturi blown out from the main nozzle mixed with air passed through the venturi and sucked into t
15. grooves will require piston replacement 23DVX20881 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 9 Periodic Maintenance Procedures Muffler Cleaning e Remove the muffler see Muffler Removal in Engine Top chapter e Scrape the carbon off the exhaust pipe A with a wire brush KE07002BS1 C e Remove the spark arrester A from the exhaust pipe of muffler B e Clean the spark arrester screen by brushing it e Install the spark arrester KE07003BS1 C Crankshaft Crankshaft Connecting Rod Inspection e Remove the crankshaft see Crankshaft Removal in Crankshaft chapter e Visually inspect for the damage on the crankshaft and connecting rod x If the crankshaft or connecting rod are damaged replace them with a new one e Install the crankshaft to the crankcase e After assembly turn the crankshaft by hand to make sure that it turns lightly www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 10 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Spark Plug Cleaning and Inspection e Remove the spark plug see Spark Plug Removal in Elec trical 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 dama
16. rod and the needle bear ing are inseparable This means that the crankshaft must 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 e Apply a fine oil to the both ball bearings A e Apply a heat resisting grease between oil seal lips B e Apply a fine oil to the connecting rod big end C e Install the crankshaft to the crankcase e Combine the crankcase see Crankcase Assembly e Install the starting pulley to the crankshaft by turning clockwise and tighten it to the specified torque Torque Starting Pulley 15 N m 1 5 kgf m 11 ft Ib KG06013BS2 C OThe recoil pawl A must be fitted on the pulley as shown B Rotating Direction viewed from recoil side KG06014BS1 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 ELECTRICAL SYSTEM 6 1 Electrical System Table of Contents Exploded VieW E 6 2 eyele ehorz LOI A EO LIE 6 4 Special TOONS zr 6 5 eg eg Ee OR A E E EE ENE 6 6 Ignition Coil Removal unid EE Eoo A Ag ee aad 6 6 Ignition De De Es AE RE OR EA N AE EE ER ET 6 6 ignition Coil IiSpectlOn ie SE RE di 6 7 Flywheel Removals mi ER be oe ee ee se tates talc ge idee BERE ea fd Uhr dete 6 7 BAM EER ME RE N OK EE N 6 8 Spark Plug REMOVAL ciii oo uten pete EL Ge oa M ote encor Ge ee RE Ge
17. tank A equal to the atmospheric pressure in order to prevent poor fuel flow caused by internal pressure drop or rise be cause of fuel use for operation or temperature change For this purpose both the tank cap B and the breather C have an air vents D as shown in the figure When cleaning the fuel tank inside check to see if no clogging is found in the air vents and breather passage If found clean or replace the parts Fuel Leakage Inspection e Visually inspect for the crack split and fuel leakage on the fuel tank A fuel tubes B tank cap C tank grommet D and carburetor E e Be sure that the inlet tube A and overflow tube B install lightly into the pipe on the carburetor Air Cleaner Element Inspection and Cleaning e Remove the air cleaner element A see Air Cleaner Re moval in Fuel System chapter e Visually inspect for the stain in the element e Clean the air cleaner element with an approved high flash point solvent only Alf the element is very stain replace it with a new one NOTE OOperating in dusty condition may require more frequent Kc068012 P maintenance than above CAUTION Improper element cleaning can result in engine damage Do not use compressed air to clean or dry element Do not oil the element CAUTION Do not operate engine with air cleaner parts re moved www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4
18. valve which opens and closes with the con trol lever movement has got some damage on its tip end or wear due to its long use applying air to the tip end of the needle valve will not be the solution for overflow In this case replace the pump body assembly with a new one Control lever height adjustment e Adjust the control lever A so as to be at the same level as the bottom of the metering camber B as shown in the figure Adjust the lever to be from 2 5 mm 0 099 in to 2 7 mm 0 106 in C with the pump body surface as standard KC05036BS1 C e Use ruler etc as a simple method to check the control lever height as shown If necessary adjust by bending the lever slightly Control Lever A Plate B KC05037BS1 Carburetor Assembly Before assembling clean the carburetor with a high flash point solvent so that no dirt enters the carburetor www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 12 FUEL SYSTEM Carburetor Priming pump check valve installation When reinstalling the priming pump check valve apply oil lightly to the valve and push the tip end of the valve lightly into the air purge body hole Put the valve in the hole by pushing the center of the check valve A hard and turning the center right and left with thumb as shown KCO5039BS1 C e Install the pump gasket pump diaphragm pump plate gasket air purge body priming pump
19. 9623 or 606 561 4983 TROUBLESHOOTING 8 1 Troubleshooting Table of Contents Engine TraublesliGOUuG eT 8 2 Hard Sastre id 8 2 Engine MalfumEuOR set sa soete oia bek eb de datada aie shunts euentu pepe ado di eaque 8 5 Insufficient PO 7 PE 8 6 Abnormal Engine NOISBS urls ag ee DA De GR GE woe os LOL RR AE Dele ede te BO RAD ge 8 6 SUI sies ee EER Rg N im labia 8 6 Fuel Leakage from Earburetor ideas pen adeste beet path Pott etr dedo vea up eda DR ee GE GR ee capu RE 8 7 Excessive Fuel Consumption ee ee ee ee ee ee ee ee ee ee ee ee ee ee 8 7 Engine Stops during Operation esse a ia 8 7 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 2 TROUBLESHOOTING Engine Troubleshooting Hard Starting Symptom Cause Remedy Pulling recoil starter grip Poor compression e Wear in piston e Replace would not cause sufficient s m e Wear in piston ring e Replace compression Stick of piston ring e Clean ring groove and replace piston ring e Wear or deformation of Replace cylinder and cylinder bore piston ring as a set e Poor tightening of cylinder e Tighten and spark plug After making several Insufficient fuel e No fuel in fuel tank e Replenish starting attempts it is found on removing spark plug that electrodes are still dry e Clogged fuel tank cap air Clean vent and breather e Clogging of dust or entry e Clean of air in fuel pipe e Foul fuel filter in
20. 983 2 8 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Top Cylinder Fins Cleaning e Remove Air Cleaner see Air Cleaner Removal in Fuel System chapter Carburetor see Carburetor Removal in Fuel System chapter Muffler see Muffler Removal in Engine Top chapter Engine Shroud see Cylinder Removal in Engine Top chapter Fan Housing see Flywheel Removal in Electrical Sys tem chapter Ignition Coil see Ignition Coil Removal in Electrical Sys tem chapter e Remove the muffler see Muffler Removal in Engine Top chapter e Clean the cylinder fins A with a wire brush or com pressed air KE06023BS1 C Cylinder Cleaning e Remove the cylinder see Cylinder Removal in Engine Top chapter e Scrape the carbon deposits inside the cylinder exhaust hole A combustion chamber B decompression hole C and decompression slot D with a suitable tool Piston Cleaning e Remove the piston and piston rings see Piston Removal in Engine Top chapter CAUTION Never clean the piston head with the engine assem bled Carbon particles will fall between the piston and cylinder and damage the crankshaft bearing e Scrape the carbon off the piston head using a scraper A 230VX20581 that made of a material that will not cause damage e Clean the piston ring grooves A with a broken piston ring or other suitable tool CAUTION Be careful not to widen the ring grooves Damaged ring
21. EE orba nia OR OR N 3 11 GarburetofAdjustinient oro S rie oct eco tube situs Ae don iue ens aeg cul linn estate Eg cd 3 12 o EU 3 13 ode Removal estoit fete OD OO EA EE ida Cea ta Pu TEETE 3 13 ClutchInstallatiOn x s lodo dl rede EE ee 3 13 OIN cm E 3 14 Fuel Tank Removal ee ee ee ee ee ee ee e ee ee ee ara ian ianao Lipna a Eiei 3 14 Fuel Tank Installation is EE e ee re eee ee het eee re sivas e ed e Tug 3 14 Fuel Tube Replacement ss ee Ee ee ee ee ee ee ee ee nnne ennemis 3 14 Fuel Filter Cleaning se EER SEE A DE EG AE dei a Bate ee 3 14 Fuel lank Cap lnspeelioN Es Ee p e ect ce eter e N ER ER EE de d dt 3 14 Fuel Leakage Inspeelion RR id 3 14 laer RE N ED 3 15 Air Cleaner Element Inspection and Cleaning esse ee ee ee RR Re ee ee ee ee 3 15 Air Cleaner Removal oir se A e Er ERR be 3 15 Air Cleaner Installation sse nemen mener nne 3 15 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 2 FUEL SYSTEM Exploded View www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 3 Exploded View A EE n WU SE mw EIE TT 3r t8 rm 2 nsulator Mounting Screws 0 38 2 7 in lb 3 Fuel Tank Mounting Screws 0 16 1 2 in Ib L 4 Clutch Pins 8 8 0 90 6 5 in lb L L Apply non permanent locking agent www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606
22. ER Ve mattered Re EE daha ke Crankshaft neret te m Rb e e EE he Crankshaft Removal onccccicococccoconconcncnnncnonononenennnnnnnonononcnnnnonnnnnnnnnnnnnnnennnnnonononenenenneninnns Crankshaft Installation ooooonconcncnccccononononononnnnnonononencncnnnnnnononanononononnnonononaneninnoninnn www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 2 CRANKSHAFT Exploded View www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CRANKSHAFT 5 3 Exploded View reme one ares 2 Starting Pulley G Apply grease 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 5 4 CRANKSHAFT Specifications Item Service Limit Ball Bearing Axial Play 0 5 mm 0 019 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CRANKSHAFT 5 5 Sealant Kawasaki Bond Silicone Sealant 56019 120 7560120ST www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 6 CRANKSHAFT Crankcase Crankcase Disassembly e Remove Cylinder see Cylinder Removal in Engine Top chapter Flywheel see Flywheel Removal in Electrical System chapter Starting Pulley e Remove the crankcase screws A and split the flywheel side crankcase B and starter s
23. For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 TJ27D Kawasaki 1 2 N N N BL a rd gt ede A Kas L 200 i 3 baza S SN 223313337 2 Stroke Air Cooled Gasoline Engine Service Manual 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 Quick Reference Guide General Information Periodic Maintenance Fuel System Engine Top End Crankshaft Electrical System Recoil Starter Troubleshooting This quick reference guide will assist you in locating a desired topic or pro cedure Bend the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the spe cific topic required 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 TJ27D Kawasaki 2 Stroke Air Cooled Gasoline Engine Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality
24. For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 2 PERIODIC MAINTENANCE Periodic Maintenance Chart A WARNING Accidental engine starting can cause injury Always remove the spark plug cap from the spark plug before servicing the engine to pre vent accidental starting Interval EE Daily First 20 Every 20 Every 50 Every 100 hours hours hours hours Check and replenish fuel e Check for fuel leakage e Eoo og Check bolts nuts and screws for looseness 2 and loss Clean fuel filter Oo e Clean fuel tank cap Clean air filter element Tighten bolts nuts and screws e Clean spark plug and adjust electrode gap e Remove dust and dirt from cylinder fins e Remove carbon deposits on piston head and inside cylinder Remove carbon deposits in the exhaust pipe 3 of muffler Clean net of spark arrester e Check the sliding portion of crankshaft a connecting rod etc Fuel tube It is recommended to replace every 3 years NOTE OThe service intervals indicated are to be used as a guide K These items must be performed with proper tools See your authorized Kawasaki dealer for service These items must be performed more frequently as necessary by operating condition www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 3 Tightening Torque The following tables list the tightening torque for the major
25. N m 0 18 kgf m 1 3 in Ib of torque and afterward tighten them with spec ified torque Torque Cylinder Bolts 3 7 N m 0 38 kgf m 2 7 in Ib e Apply a non permanent locking agent to the engine shroud mounting screw e Install the engine shroud and then tighten the engine shroud mounting screw Torque Engine Shroud Mounting Screw 2 7 N m 0 28 kgf m 2 0 in Ib e Install the removed parts Cylinder Fins Cleaning e Refer to the Cylinder Fins Cleaning in Periodic Mainte nance chapter Cylinder Cleaning e Refer to the Cylinder Cleaning in Periodic Maintenance chapter Piston Removal CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Remove Flywheel see Flywheel Removal in Electrical System chapter Cylinder see Cylinder Removal e Remove the snap rings A from the piston B e Pull out the piston pin C from the piston and remove the piston and the needle bearing D out of the small end of the connecting rod E e Remove the piston rings out of the piston KE06024BS1 C Piston Installation e Install the piston rings A that ring fit at the piston ring B stopper B in the piston groove Q OTop and second ring are common rings 23DVX31781 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 4 7 Cylinder Piston e Fit the needle
26. age CAUTION Do not remove the main nozzle as itis 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 KC05035BS1 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 10 FUEL SYSTEM Carburetor e Unscrew the diaphragm cover screws and remove the diaphragm cover and main diaphragm Check to see if main diaphragm is not rapped If the diaphragm or gasket is damaged replace with new parts e Unscrew the lever pin screw and remove the control lever lever pin needle valve and spring Priming pump check valve removal ODo not remove check valve installed into priming pump cover normally If it is removed because of clogging with dust and so on take care not to damage seat surface to check valve and contact area of the valve OWhen removing the check valve do not use tip of screw driver metal and the like e When replacing the priming pump check valve installed on the air purge body pinch the check valve A with care so that it does not get damage KC05038BS1 C Carburetor Inspection e Clean the carburetor with cleaning oil and apply air e Check and 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 a new one e As to the gaskets check to see if no deformation or dam ag
27. and priming pump cover onto the carburetor body e Install the control lever spring needle valve control lever and control lever pin and fix pin with screw Push tip of control lever lightly to check the smooth movement of the lever e Check the control lever height see Control lever height adjustment in this chapter e Install the throttle valve assembly onto the carburetor body take care about the installing direction and tighten the two throttle collar screws Carburetor Adjustment Adjustment is not normally necessary But if the engine runs in an unstable condition see Troubleshooting in this chapter www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 13 Clutch Clutch Removal e Keeping the clutch shoes A from turning by using a pair of pliers release the clutch pins B by turning counter clockwise to remove the clutch assembly OTake care not to scratch the clutch shoes A ODo not remove the clutch spring C if not needed KC08010BS1 C Clutch Installation e Apply locking agent to screw threads of the clutch pins e Apply bit of heat resisting grease to the clutch pin holes e Put the clutch shoes nad the plate on the flywheel with raised letter such as R54 toward you to install them by tightening the clutch pins to the specified torque Torque Clutch Pins 8 8 N m 0 90 kgf m 6 5 in Ib e Install the clutch spring to the clutch shoes be
28. aning ee EE A Ra dat e ee ER Ee 4 6 Cylinder Cleaning su A De vobia totae ed 4 6 Piston Removal sr EE NE Lass RE SERE ede Be N SG eN Ge Ge EE aeri ei Ge ee desu ER do 4 6 Piston Install Est A ee EE eg ee teen ee EE ER Ge EE Se TRE Tue ef 4 6 A ie EE MP 4 7 MU ti A A RE eg ES DE Ne Re 4 8 M ifler Removal EE EE AS EG EE ehe eor ti d Re ee ee RE N Ee ERE ba 4 8 Muffler Installation wees N N EE rie es 4 8 Muftler Cleanings IE RR AE EE OR rales 4 8 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 2 ENGINE TOP END Exploded View www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 4 3 Exploded View EA ue Ed Engine Shroud Mounting Screw 2 0 in Ib 2 Cylinder Bolts 0 38 2 7 in lb 3 Muffler Mounting Bolts 37 0 38 2 7 in lb L L Apply non permanent locking agent O Apply engine oil www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 4 ENGINE TOP END Specifications Item Service Limit Cylinder Piston Cylinder Bore 34 1 mm 1 342 in Piston to cylinder Clearance 0 15 mm 0 0059 in Piston Ring to goove Clearance 0 17 mm 0 0067 in Piston Ring End gap 0 7 mm 0 0028 in Piston to piston Pin Clearance 0 1 mm 0 0039 in Connecting Rod Big end Radial Play 0 15 mm 0 0059 in Piston Pin to needle Bearing Radial Play 0 15 mm 0 0059 in www mymowerparts com Fo
29. cturer 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 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 3 Before Servicing 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 and Cotter Pin When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more Install the circlip with its chamfered side facing load side as well Replace any circlips retaining rings and cotter pins that were removed with new ones as re moval weakens and deforms them If old ones are reused they could become detached while running leading to a problem 14 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 a
30. dic Maintenance Chart ee ene ee ee ee ee ee ee ee ee ee 2 2 Tightening Tor qUe ss E 2 3 SDSOIfICatioliS 14 AE AA E EE OK N 2 4 Special Tools and Sealant ese ee ee Re Ee EE ee ee ee ee EE ee ee ee ee ee sese ee ee ee ee a ee ee ee 2 5 Periodic Maintenance ProcedureS sis sekere ede ee see Ge Re ER ed Ee ee ee kke de nite thea keen nn ee ae 2 6 dcc CIIM m 2 6 ding Speed Adjustment avis ae RR REEL Mate DA AE 2 6 Fuel Tube Replacement ccccceccceccceeeceeeeeeceeeeeeeeeeeeeseeegeeeeeeeeeeeeeeeeeeeeeeenseeseeeeseeeseenseeess 2 6 Fuel Filter Cleanind su ESE AD Ge de ee Re tutu sa Gee Pose bue tnt Debe bathe eden 2 6 Fuel Tank Cap Inspection ee memes 2 7 Fuel Leakage Inspections er OR aa Mute tae Ee bou Lua ER dta ua nud 2 7 Air Cleaner Element Inspection and Cleaning esse ee ee RR Re ee ee ee 2 7 O Sons Me ely Beara ale See Racer ceeded ee rene 2 8 Cylinder Eins Cleaning 2535 0 RE dks do t ee centeno N Ee EN ee i EER ER EE ee Gereg ee Ee ee ie 2 8 GyliniderEleanifig T 2 8 dele EE N OE OE OR RE OR EA N 2 8 i ume mmm Em 2 9 A A E E 2 9 Crankshaft Connecting Rod Inspection ee ee ee Re ee ee ee Re ee ee ee 2 9 Electrical Sysleri id dote cec es ER ee ut oet Roscoe deduc al ad taedet 2 10 Spark Plug Cleaning and INSpectiON coccccccccnnccnnncnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnss 2 10 Spark Plug Gap Inspection and Adjustment ee ee ee ee ee 2 10 www mymowerparts com
31. e transistor Q1 base and thereby exciting the transistor base Thus the transistor forms turns ON the primary circuit This circuit current flows from the plus side of the primary winding to ground through the transistor CollectorC to Emitter E When the base current is flowing the trigger sensor TS1 detects optimum time peak current to shut off the transistor base current With the transistor rapidly shutting off the current at the primary coil counter electromotive force is generated and voltage in hundreds volts is induced through the primary winding L1 thereby producing extremely high voltage at the secondary winding L2 When this secondary voltage steps up to k volts ionization meaning ignition occurs across the electrodes at the spark plug SP The trigger sensor located internally in the ignition system is set to give constant ignition timing according to engine speed and temperature When the stop switch SW is set at the closed position primary voltage is routed to ground not allowing igniting operation www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 10 ELECTRICAL SYSTEM Ignition System Spark Plug Removal e Pull the spark plug cap A in the direction shown and remove it from the spark plug e Remove the spark plug using a suitable plug wrench Spark Plug Installation e Screw the spark plug gently into the plug hole with the plug installed in
32. e is found If deformation or damage is found replace them with new ones e Check the pump diaphragm to see if no damage or hard ening is found Check the inlet check 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 aluminum plate bend x If there is any replace it with a new one After cleaning the pump body check to see that the con trol lever functions well and the lever height is correct Also check to see that the main check valve works well and that no dirt is found on the inlet screen CAUTION Do not use compressed air the valve www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 11 Carburetor Main check valve function check e To check function of the main check valve stick vinyl pipe end to the main check valve and breather in and out from the other end Alf the valve opens when breathing in and closes when breathing out the valve functions well e If any problems are found soak the valve in gasoline for about 10 minutes and repeat breathing in and out several times Alf no improvement shows replace the pump body with a new one Control lever function check and needle valve wear e Push the tip end of the control lever lightly and make sure that the lever moves smoothly x If the needle
33. fasteners and the parts requiring use of a non permanent locking agent or liquid gasket Letters used in the following Tightening Torque table mean L Apply a non permanent locking agent to the threads LG Apply a liquid gasket to the sealing surface Tightening Torque Fasteners Fuel Tank ml i M M i M i M M M M M Size N m Torque kgf m 0 22 0 18 0 38 0 28 0 38 0 38 0 16 0 38 ft lb 1 6 in Ib 1 3 in Ib 2 7 in lb 2 0 in Ib 2 7 in lb 2 7 in lb 2 7 in lb 1 2 in lb 2 7 in lb 2 7 in lb Remarks Cylinder 0 38 Clutch M 0 90 6 5 in Ib Flywheel Nut M 1 50 11 Starting Pulley M6 15 1 50 11 Spark Plug M14 14 1 50 11 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 2 2 1 8 5 3 7 5 2 7 5 3 7 5 3 7 038 5 1 6 5 3 7 5 3 7 6 8 8 8 15 Threads dia mm 4 2 0 0 20 17 in lb 5 3 4 0 35 30 in lb 6 5 9 0 60 52 in Ib 8 15 1 5 11 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 4 PERIODIC MAINTENANCE Specifications Item Standard Fuel System Maximum Speed Different depend on matching machine Idling Speed 3 000 200 r min rpm Air Cleaner Type Dry type Ca
34. fore in stalling the clutch shoes on the flywheel if the clutch spring is removed www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 14 FUEL SYSTEM Fuel Tank Fuel Tank Removal e Unscrew the fuel tube clamps and remove the fuel tubes e Unscrew the screws A and remove the stand B and the fuel tank C e Remove the tank grommet A together with the fuel tubes B from the fuel tank C e Remove the clamp E and remove the fuel filter D from the fuel tube Fuel Tank Installation e Install the fuel filter to the long fuel tube and fix it by the clamp A e Insert on the part of installed fuel filter to the tank inside and insert the fuel tube assembled tank grommet B to the grommet hole on the fuel tank NOTE OApply a bit of 2 stroke engine oil to the grommet in order to make the insertion easy K608007851 0 Olnstall the grommet as raised letter face to the fuel tank outside e Apply a non permanent locking agent to the stand mount ing screws and install the fuel tank Torque Fuel Tank Mounting Screws 1 6 N m 0 16 kgf m 1 2 in lb e Fix the fuel tube to the carburetor by the clamp Fuel Tube Replacement e Refer to the Fuel Tube Replacement in Periodic Mainte nance chapter Fuel Filter Cleaning e Refer to the Fuel Filter Cleaning in Periodic Maintenance chapter Fuel Tank Cap Inspection e Refer to the Fuel Tank Cap Inspection in Periodic Main
35. fuel tank Clean e Air entering at gasket e Tighten or replace fitted to carburetor flange gasket e Clogged carburetor e Clean needle jet or main jet After making several Excess fuel e Faulty starter button e Remove spark plug starting attempts it is pushing In summer or with engine switch found on removing spark when engine is warm OFF exhaust excess plug that electrodes are starter button pushing fuel by pulling starter excessively wet gives too rich mixture rope e Overflow of fuel from e Check carburetor and carburetor exhaust excess fuel from cylinder e Clogged air cleaner e Clean air cleaner and exhaust excess fuel from cylinder On removing spark plug Faulty fuel e Mixture of water into fuel e Change fuel moisture condensed on e Deterioration in fuel e Change fuel spark plug electrodes g because of poor long term storage e Use of fuel other than Change fuel designated Make spark check Faulty spark plug e Electrodes are burned e Correct gap or No spark but spark and damaged to cause replace appears on spark plug too wide gap replaced e Much carbon bridging e Clean or replace electrodes gap e Small foreign matter e Clean being caught between electrodes e Faulty insulation of e Clean or replace electrodes spark plug www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING 8 3 Engine Troubleshooting Tm e Looseness of ter
36. ged or if the insulator is cracked replace the spark plug with a new one Use the standard spark plug or its equivalent A Insulator B Center Electrode C Plug Gap D Side Electrode Standard NGK BPMR6A Spark Plug Gap Inspection and Adjustment e Measure the plug gap C of the center electrode B and or side electrode D are regulation range with a wire type thickness gauge Spark Plug Gap Standard 0 6 0 7 mm 0 024 0 028 in e When spark plug gap is except standard adjustment side electrode is bent carefully e Install the spark plug see Spark Plug Installation in Elec trical System chapter e Pull up the spark plug cap lightly to make sure of the in stallation of the spark plug cap S N DO N SK OD iy SA SSSSS 27 SNNN YS KI ll ES E GP10012381 C 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 E SPSCINGALIONS Ses EE E A A EO OE LE AAT 3 4 CarbUretOn MM 3 5 Idling Speed Adjustment cette oc TE eed eret ip tack EG Ge Ge ER Ee tuat bg ees ede ds 3 5 Carburetor Removal re RE NEG toc eie tete reda GE Gee t rcv Gee ERE Re ER ee 3 5 eed LENIE ei neret nter nennen nnne nns 3 5 Carburetor Disassembly 1 EE eene b iaa 3 9 Carburetor Inspection co ether geo t eir EE IS EVER ute EE beds 3 10 Carburetor Assernbly rrr
37. hamber e Dust accumulation on cooling fins of cylinder Faulty electrical system Cranking is easy e Faulty spark plug e Faulty magneto e Looseness in connections e Faulty ignition coil e Adjust carburetor e Change fuel e Clean e Clean e Clean or replace e Replace e Check and repair e Replace Faulty fuel system e Clogged fuel line e Foul air cleaner e Fuel in tank used up e Dust clogging in fuel e Clean passage Faulty carburetor www mymowerparts com e Clean e Clean or replace e Replenish For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 NX Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 2064 01 Printed in Japan www mymowerparts com
38. he engine When the engine stops negative pressure in the venturi becomes zero the control lever is pushed up with the valve spring and the needle valve closes Then fuel flow stops and overflow is prevented www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 9 Carburetor Plate Screw Plate Priming Pump Priming Pump Check Valve Air Purge Body Filter Gasket Pump Plate Pump Diaphragm 10 Gasket 11 Diaphragm Cover Screw 12 Diaphragm Cover 13 Main Diaphragm 14 Lever Pin Screw 15 Control Lever 16 Needle Valve 17 Lever Pin 18 Valve Spring 19 Carburetor Body 20 O ring 21 Throttle Valve Assy 22 Throttle Collar Screw 23 Idle Adjust Screw 24 Starter Button 25 Spring 26 Lever End 27 Washer 28 Snap Ring 29 Cable Adjuster OPADAALNS KCO05032BS2 C Carburetor Disassembly Before disassembling clean the carburetor with a high flash point solvent so that no dirt enters the carburetor e Remove the 2 throttle collar screws to remove the throttle valve assembly and O ring from the carburetor body CAUTION Do not disassemble the throttle valve assembly e Remove 4 plate screws e Remove the plate priming pump air purge body gasket plate pump diaphragm and gasket in that order OBlow air against pulse hole A to see if pulse passage is not clogged and confirm outflow of air from the other side of the pass
39. he point shown and read the resistance Alf the resistance is not as specified replace the ignition coil x lf the meter reads as specified the ignition coil windings probably is 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 KH08004BS1 C Resistance between A B C A 5 0 7 0 kQ 600 800 MQ B 5 0 7 0 kQ 5 0 7 0 kQ C 600 800 MO 5 0 7 0 kQ NOTE Olt is unable to inspect the igniter whether it is good or bad with the Kawasaki hand tester since it was inte grated with the ignition coil OWhenever you have doubt as to function of the igniter to operate try replacing the ignition coil with one known to be good Flywheel Removal e Unscrew the fan housing screws A and remove the fan housing B www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 8 ELECTRICAL SYSTEM Ignition System e Remove Fuel Tank see Fuel Tank Removal in Fuel System chap ter Air Cleaner see Air Cleaner Removal in Fuel System chapter Carburetor see Carburetor Removal in Fuel System chapter Muffler see Muffler Removal in Engine Top chapter Engine Shroud see Cylinder Removal in Engine Top chapter MMOSBOM F Ignition Coil see Ignition Coil Removal in this chapter e Release the flywheel nut A counterclockwise to remo
40. ide crankcase C Olf the crankcase is hard to split lightly tap the crankcase with a plastic hammer ene OTake care not to damage the oil seals Crankcase Assembly e f the original crankcase is reused removed liquid gasket must be cleaned thoroughly to secure airtight e Sparingly apply liquid gasket on the sealing surface A of the PTO shaft side of the crankcase Sealant Kawasaki Bond Silicone Sealant 56019 120 CAUTION Excessive amounts may block something inside and cause serious damage e Install the crankshaft to the crankcase see Crankshaft Installation in this chapter OTake care not to damage the oil seals KG04012BS1 C e Make sure that dowel pins are in place and combine the flywheel side crankcase and starter side crankcase and tighten the screws to the specified torque evenly in the order as shown Torque Crankcase Screws 3 7 Nm 0 38 kgf m 2 7 in Ib e Install the removed parts www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CRANKSHAFT 5 7 Crankshaft Crankshaft Removal e Remove Cylinder see Cylinder Removal in Engine Top chapter Flywheel see Flywheel Removal in Electrical System chapter e Remove the starting pulley A from the crankshaft by turn ing itself counterclockwise e Split the crankcase assembly see Crankcase Disassem bly e Remove the crankshaft Crankshaft Installation The crankshaft the connecting
41. inside and insert the fuel tube assembled tank grommet to the grommet hole on the fuel tank NOTE OApply a bit of 2 stroke engine oil to the grommet in order to make the insertion easy Fuel Filter Cleaning e Remove the fuel filter A together with the grommet C from the fuel tank B e Remove the fuel filter from the fuel tube see Fuel Tank Removal in Fuel System chapter OThe filter is caulked and unable to be disassembled e Clean the fuel filter in a bath of high flash point solvent e Dry the fuel filter before installing as dust does not adhere OThis fuel filter is double filtration and prevents dirt from clogging in the foul passage inside the carburetor If the filter gets foul clean it in pure gasoline and apply air from the outlet of the filter body If the filter is still foul replace it with a new one A Filter Body B Secondary Filter C Primary Filter D Washer NOTE Olf fuel does not flow better with the fuel filter cleaned replace the fuel filter with a new one KC05028BS1 C KC08008BS1 C 77 lt lt ye Y WEN A E npn 7 gt Sp 7 23DVX508S1 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 7 Periodic Maintenance Procedures Fuel Tank Cap Inspection OThe tank cap works as a lid for the fuel inlet It also needs to work to keep the internal pressure of the fuel
42. leaner see Air Cleaner Removal in Fuel System chapter Carburetor see Carburetor Removal in Fuel System chapter e Remove the ignition coil lead wire A from the clamp B and disconnect the ignition coil lead wire KHM08BO 4 P e Unscrew the ignition coil mounting bolts A and remove the ignition coil B Ignition Coil Installation e Install the ignition coil as shown A Ignition Coil Lead Wire B Ignition Coil C Ignition Coil Mounting Bolts e Adjust the ignition coil air gap A to the standard value with a thickness gauge and install the ignition coil Ignition Air Gap Standard 0 3 0 5 mm 0 012 0 019 in e Tighten the ignition coil mounting bolts Torque Ignition Coil Mounting Screws 2 2 N m 0 22 kgf m 1 6 in Ib e Install the fan housing see Flywheel Installation e Install the ignition coil wire lead to the clamp e Install the removed parts KH08005BS1 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 6 7 Ignition System Ignition Coil Inspection e Remove the ignition coil see Ignition Coil Removal in this chapter OThe ignition coil has been integrated with an igniter being solid state OUse the Kawasaki hand tester Resistance value may vary with individual meters Special Tool Hand Tester 57001 1394 e Set the Kawasaki hand tester to the specified range 100 Q e Connect the test lead to t
43. minal e Tighten securely Provided that only spare parts No spark in any spark Faulty plug cap eFaulty contacting at spark e Remove plug cap plug but spark appears plug cap and connect terminal when the end of high again tension cord is touched to engine block No fuel drains into the e Clogging in fuel tube at inlet side e Clean the tube return pipe in spite Rd e Broken tube at inlet side e Replace of several priming operation e Air leakage from joint portion of fuel tube at e Fit fuel tube to the inlet side joint or replace e Adhesion of dust to check valve of priming e Disassembly and pump clean parts e Broken check valve of priming pump or e Replace damaged seat surface of pump cover e Air leakage from fitting area of priming pump e Tighten e Broken priming pump e Replace e Air leakage from main check valve e Disassembly and clean the check valve If not good replace the main check valve and plate e Loosen main diaphragm cover e Tighten e Broken main diaphragm e Replace Fuel drains into the return e Clogged air filter e Clean pipe by priming operation e Clogged needle jet e Dissemble and clean but engine does not start e Overflow of fuel from needle jet to the venturi e Clean or replace of carburetor After starting engine e Clogged pulse passage e Clean revolution does not e Improper height of control lever e Adjust continue www mymowerparts com For Kawasaki Discount
44. nd 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 15 Electrical Wires All the electrical wires are either single color or two color and with only a few exceptions must be connected to wires of the same color On any of the two color wires there is a greater amount of one color and a lesser amount of a second color so a two color wire is identified by first the primary color and then the secondary color For example a yellow wire with thin red stripes is referred to as a yellow red wire it would be a red yellow wire if the colors were reversed to make red the main color Wire cross section Color Indicated on the Wire Color Indicated on the Wiring Diagram Red Wire Strands Yellow Red Yellow Red 6B020601w1 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
45. on of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 1 General Information Table of Contents Belore SerVICIIg EE uota sete ee Ee ie Eed cian cunt launder Anan idet ido sae shut ue iere Ged EE buts 1 2 Model ldentificatiON ee EE RE EE EE Ee ee ee GR Ee GR Ee GR Ee ee ee ee ee ee ee ee ee ee ee ee nennen 1 4 General Specifications ns coe cm ee AR EES ADS RS Ge ei Meets Seen Helin Ge E e ee dean 1 5 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 in cluded wherever necessary Nevertheless even a detailed account has limitations a certain amount of basic knowledge is required for successful work Especially note the following 1 Dirt Before removal and disassembly clean the engine Any dirt entering the engine carburetor or other parts will work as an abrasive and shorten the life of engine For the same reason before installing a new part clean off any dust or metal filings
46. onnecting rod noise e Wear in large and small end bearings e Replace Crankshaft Assy Surging Symptom Cause Remedy Surging e Foul air cleaner e Clean e Dust clogging in or air entry into fuel pipe e Clean e Clogged fuel tank cap air vent and breather e Clean e Clogged carburetor e Clean www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING 8 7 Engine Troubleshooting Fuel Leakage from Carburetor Symptom Cause Remedy Fuel leak from carburetor e Foreign matter attached to needle valve and or valve seat e Correction or wear in needle valve and or valve seat e Poor tightening of diaphragm gasket e Clean e Replace needle valve assembly e Tighten or replace Excessive Fuel Consumption an e Same as Hard Same as Hard Starting e Poor e Same as Hard Starting compression Starting Sufficient compression e Too rich fuel mixture e Agjust but excessive fuel consumption e Inferior fuel e Replace e Foul air cleaner e Clean e Too high idling speed e Adjust Same as Fuel Leakage e Same as Fuel Leakage from Carburetor from Carburetor e Same as Fuel Leakage from Carburetor Engine Stops during Operation Symptom Cause Difficulty in cranking or Overheat e Excessively lean fuel seizure mixture too little fuel e Inferior lubricating oil mixed e Excessive carbon deposit in combustion c
47. ply non permanent locking agent www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 4 RECOIL STARTER Kar Recoil Starter Kar Recoil Starter This recoil starter is more simplified when starting the en gine against a past recoil starter The damper spring C located between the reel A and cam plate B is bent by the engine starting torque when the starter grip is pulled The peak load is eased when starting engine by the effect of this damper spring The compression load of the second and third rotation is absorbed by the damper spring More over the rotational speed of the engine crankshaft rises and the engine can be started easily even at the same rope pull speed as a past model This recoil starter is lightness and a compact type Recoil Starter Removal e Unscrew the recoil starer mounting screws A and screw B and remove the recoil starter C KHOOBOIA P Recoil Starter Installation e Apply a non permanent locking agent to the recoil starter mounting screws and install the recoil starter Torque Recoil Starter Mounting Screws 1 8 N m 0 18 kgf m 1 3 in Ib Recoil Starter Disassembly e Remove the recoil starter see Recoil Starter Removal e Pull out the rope end about 300 mm 11 81 in and make a temporary knot A at that point e Pull out the rope end from the starter grip B and untie the knot C at the rope end to remove the grip www mymowerpart
48. r Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 4 5 Cylinder Piston Cylinder Removal e Pull the spark plug cap A in the direction shown and remove it from the spark plug e Unscrew the shroud mounting screw B to remove the engine shroud C e Remove the recoil starter see Recoil Starter Removal in Recoil Starter chapter e Remove the engine shroud e Remove Fuel Tank see Fuel Tank Removal in Fuel System chap ter Air Cleaner see Air Cleaner Removal in Fuel System chapter Carburetor see Carburetor Removal in Fuel System chapter Muffler see Muffler Removal in Engine Top chapter Ignition Coil see Ignition Coil Removal in Electrical Sys tem chapter e Unscrew the cylinder bolts A and remove the cylinder B and cylinder gasket C from the crankcase e Check to see if the pulse hole D is clogged e If pulse hole clogged clean it Cylinder Installation e Apply a non permanent locking agent to the cylinder bolts e Apply engine oil to the piston and sliding surfaces e Replace the cylinder gasket with a new one and install the cylinder and cylinder gasket OSet the cylinder gasket noting its profile A for scavenging port B Air Cleaner Side C Muffler Side 23DVX31581 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 6 ENGINE TOP END Cylinder Piston e First tighten each cylinder bolt with 1 8
49. rburetor Main Jet 40 Electrical System Spark Plug Gap 0 6 0 7 mm 0 024 0 028 in Ignition Coil Air gap 0 3 0 5 mm 0 012 0 020 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 Special Tools and Sealant Hand Tester 57001 1394 7571394ST C Flywheel Puller 57001 6002 75760028T PERIODIC MAINTENANCE 2 5 Kawasaki Bond Silicone Sealant 56019 120 7560120ST C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 6 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Idling Speed Adjustment e Start the engine and leave it running at idling speed to warm it up thoroughly e Adjust the throttle stop screw A until a stable running condition is obtained at the lowest speed possible Idling Speed 3 000 200 r min rpm Throttle Stop Screw Turning clockwise Revolution rises Turning counterclockwise Revolution drops Fuel Tube Replacement e Remove the fuel tube that they are assembled inlet pipe and outlet pipe on the carburetor e Remove the tank grommet A together with the fuel tubes B from the fuel tank C e Remove the fuel filter D from the fuel tube e Replace the fuel tube with a new one and through it to the grommet hole e Install the fuel filter to the long fuel tube and fix it by the clamp E e Insert on the part of installed fuel filter to the tank
50. rburetor body at the opposite side of the pump chamber The engine pulse to actuate pump diaphragm is introduced into this chamber 8 Needle valve This valve moving along with the operation of main diaphragm controls fuel flow from fuel pump into metering chamber 9 Main diaphragm Main diaphragm is pulled up towards the carburetor body by the engine inlet pressure negative pressure applied through needle jet from the carburetor venturi and this movement opens needle valve through control lever 10 Control lever Control lever transmits the movement of main diaphragm to needle valve linked with the lever 11 Control lever spring This spring works to keep control lever in contact with main diaphragm 12 Metering chamber This chamber is formed between main diaphragm and the carburetor body and performs func tions of drawing fuel into the chamber and keeping fuel in the chamber at constant volume by the operation of the diaphragm 13 Air vent To make the diaphragm movement smooth the hole is exposed to the atmosphere 14 Priming pump Pushed repeatedly by hand the pump sucks fuel into the metering chamber from the fuel tank and discharges the air 15 Priming pump check valve This valve works with the operation of priming pump and opens for only flow from metering cham ber to fuel outlet 16 Fuel outlet port Overflow of fuel sucked up from metering chamber by operating priming pump drains through this outlet and flows back into the f
51. retor and internal parts e Spark plug e Magneto or electronic ignition system e Fuel filter e Air cleaner element 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 informa tion to make it useful to the owner who desires to perform his own basic maintenance and re pair work A basic knowledge of mechanics the proper use of tools and workshop procedures must be understood in order to carry out main tenance and repair satisfactorily Whenever the owner has insufficient experience or has 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 thor oughly familiarize yourself with the procedures before starting work and then do the work care fully 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 ad versely affect safe operation To get the longest life out of your equipment e Follow the Periodic Maintenance Chart in the Service Manual eBe alert for problems and non scheduled maintenance e Use proper tools and genuine Ka
52. retor gasket e Incomplete fitting of carburetor e Faulty ignition system e Faulty insulation of spark plug e Foul electrodes e Faulty magneto e Faulty ignition coil e Clogging in carburetor inside e Disassemble and clean e Clean or replace e Replace e Tighten Loaded operation causes revolution fluctuation with big frequency Unstable idling and the running does not continue e Clogged fuel tank cap air vent and breather e Dust clogging in or entry of air into fuel pipe or carburetor e Air entering engine through the fitting portion of carburetor e Too low idling speed rpm e Clogged main check valve e Clogged needle jet or main jet e Improper height of control lever e Tighten e Adjust e Disassemble and clean e Disassemble and clean e Adjust Engine does not accelerate in spite of opening throttle valve e Clogged air filter e Clogging in fuel tube at inlet side e Fuel passage or pulse passage of fuel pump is clogged e Clogged needle jet or main jet e Clogged main check valve e Improper height of control lever e Clean the filter e Clean e Disassemble and clean e Disassemble and clean e Disassemble and clean e Adjust Unstable revolution at high speed e Clogged air filter e Clogged in fuel tube at inlet side e Fuel passage or pulse passage of fuel pump is clogged e Clogged needle jet or main jet e Clogged main check valve e Improper height of con
53. s com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 RECOIL STARTER 7 5 Kar Recoil Starter e Holding the reel A with hand untie the temporary knot e If the rope end winds back at a one there is likely to be a broken recoil spring under the reel First release the thumb little by little until the rope length is about 30 mm 1 18 in C from the rope guide B to the rope end and then wind off the reel slowly e After confirming that no tension of recoil spring can be felt remove the recoil starter set screw A cam plate B and damping spring C holding the case lightly by hand for fear that recoil spring should come up from case e The free end of recoil spring A is hooked with reel tab Make sure by turning reel a little in the counterclockwise reel is unhooked before removing it Next carefully lift reel straight up out of case Recoil spring wound up re mains in the case Be careful that recoil spring does not fly loose and injure you It is under big pressure NOTE OThere should be no spring tension on reel when remov ing reel If tension is felt push reel back into place and gently wiggle it until reel may be easily removed CAUTION Do not remove the recoil spring except when the parts replacement is necessary A WARNING In removing and installing the recoil spring protect your hands with gloves The recoil spring that flies loose can injure you
54. the insulator and install the new insulator gasket C and insulator to the cylinder D e Tighten the insulator mounting screws E Torque Insulator Mounting Screws 3 7 N m 0 38 kgf m 2 7 in lb KC05031BS1 C CAUTION Engine pulse hole must align to prevent the engine malfunction or hard starting from the gap between the pulse hole of the gaskets insulator and cylin der e Replace the carburetor gasket with a new one and install the carburetor gasket carburetor and air cleaner case Torque Carburetor Mounting Screws 3 7 N m 0 38 kgf m 2 7 in Ib e Install the air cleaner element and air cleaner cap see Air Cleaner Installation in this chapter www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 6 FUEL SYSTEM Carburetor N SN N SSSS ae EE YA ZIZZ LY MES YE AF VA WS SN SS SSS i SA O SEREPEEEEED AM bes oe SS d T SS 9 9 9 G 5 SES Es AA Fuel Fa Ei Air Crank Pulse YOOOVO l gt SSS r m AAN SS SS SS S00 C5 5 8 9 2 92 9 SES SES SSSSSSSES ASSSSSM SS C ua IN 0 T KC05033BW2 1 Fuel Inlet Port 14 Priming Pump 2 Filter 15 Priming Pump Check Valve 3 Pump Diaphragm 16 Fuel Outlet Port 4 Inlet Check Valve 17 Main Check Vavle 5 Outlet Check Valve 18 Main Jet 6 Pump Chamber 19 Needle
55. the plug wrench e Tighten the plug Torque Spark Plug 14 N m 1 5 kgf m 11 ft Ib e Fit the plug cap securely e Pull up the spark plug cap lightly to make sure of the in stallation of the spark plug cap Spark Plug Cleaning and Inspection e Refer to the Spark Plug Cleaning and Inspection in the Periodic Maintenance Chapter Spark Plug Gap Inspection e Refer to the Spark Plug Gap Inspection in the Periodic Maintenance Chapter www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 RECOIL STARTER 7 1 Recoil Starter Table of Contents Exploded rS 7 2 Kar RecoilStarter EE ete et em tee eie Oti em Ee 7 4 Kar Rocak Starter eter Met aca EG RE a dro de aL ea om or ed 7 4 Recoil Starter Removal ees ee ee ee ee ee ee ee eee ee ee ee RR ee ee ee ee ee e neni ases sanas ee ee 7 4 Recoil Starter Installation ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee Re ee ee ee 7 4 Recoil Starter Disassembly acid diria SE ee tddi eise pedet ae 7 4 Recol Starter Assembly iss SESSE A AS 7 6 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 2 RECOIL STARTER Exploded View KJO2000BH3 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 RECOIL STARTER 7 3 Exploded View O ee LI pesisameWemmgSeen 18 038 Pisin i 2 Recoil Starter Set Screw 0 35 30 in lb G Apply grease L Ap
56. trol lever e Clean e Remove and clean e Disassemble and clean e Disassemble and clean e Disassemble and clean e Adjust www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 6 TROUBLESHOOTING Engine Troubleshooting Insufficient Power Symptom Cause Remedy Same as Hard Starting e Poor Same as Hard Starting Same as Hard compression Starting e Insufficient fuel e Excess fuel e Faulty fuel e Faulty magneto e Faulty ignition coil Engine overheated e Clogged air cleaner e Clean e Carbon deposit inside combustion chamber e Clean e Inappropriate mixing ratio too little oil e Change fuel e Broken cooling fan blade e Replace e Dirt or dust attached to cooling fins of cylinder e Clean e Grass or dirt attached to cooling air passage e Clean and flywheel blade Thick smoke issues from Excess fuel e Same as Hard Starting e Same as Hard exhaust port Starting Faulty exhaust e Carbon deposit narrows e Clean system exhaust passage and muffler e Excessive oil mixed e Change fuel Engine knocking e Inferior fuel e Change fuel Abnormal Engine Noises Symptom Cause Remedy Piston Slapping e Cylinder and piston ring wear e Replace e Wear and or deformation in piston e Replace e Carbon deposit inside combustion chamber e Clean e Wear in piston pin and connecting rod small e Replace end bearing e Wear in piston and piston pin e Replace C
57. uel tank 17 Main check valve During priming pump operation the valve prevents air from entering the metering chamber through the nozzle 18 Main jet Fuel at high speed is controlled 19 Needle jet Fuel jet hole Fuel in metering chamber is drawn by the negative pressure in the carburetor venturi flows out of needle jet through main adjust screw portion and is sucked into the engine cylinder in form of air fuel mixture 20 Throttle valve Throttle valve controls the air fuel mix supplied to the engine and controls engine output 21 Jet needle Jet needle is installed to throttle valve and the opening area between this needle and needle jet changes with the movement of the throttle valve 22 Starter button Increase the air and fuel when the engine starts 23 Idle adjust screw Turning this screw changes minimum opening of throttle valve to adjust the idling speed of the engine 24 Cable adjuster This is a sort of hollow bolt of adjusting play of the throttle wire 25 Throttle lever Throttle valve and jet needle are moved at the same time with the throttle lever www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 8 FUEL SYSTEM Carburetor Operation of Carburetor Priming Pump System When starting the engine by pushing the priming pump air is pushed out toward the overflow pipe from the priming check valve which causes negative pressure inside the metering chamber and the needle valve opens Then
58. ve it e Remove the flywheel A by using a flywheel puller B as shown Special Tool Flywheel Puller 57001 6002 Flywheel Installation e Fit the flywheel A to the crankshaft B so that the key part C drops in the key way D e Tighten the flywheel nut by turning clockwise Torque Flywheel Nut 15 N m 1 5 kgf m 11 ft lb e Install the fan housing and tighten the screws Torque Fan Housing Screws 3 7 Nm 0 38 kgf m 2 7 in Ib e Install the removed parts www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 6 9 Ignition System This engine ignition is controlled by a solid state ignition assembly and requires no periodic main tenance except for the spark plug The system consists of the following Inductive Ignition Assemblies Permanent Magnet Flywheel Spark Plug Stop Switch COW Rotation Co Core Lamination TS1 Trigger Sensor L1 Primary Coil SP Spark Plug L2 Secondary Coil SW Stop Switch Q1 Transistor F Flywheel B Base M Magnet C Collector N North Pole E Emitter S South Pole R1 Control Resistor Ignition System Operation Theory Permanent magnets are mounted around the edge area of a flywheel As the flywheel magnetic pole rotates clockwise and passes the ignition module on a laminated core group voltage is produced at the primary winding L1 allowing a small bias current to flow from the control resister R1 to th
59. wasaki en gine parts Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t take shortcuts e Remember to keep complete records of main tenance 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 A WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not strictly observed could result in dam age 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 informa tion NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a WARNING CAU TION or NOTE x Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view illustrati

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