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印刷プレビュー - Kawasaki

1. KD10000BS2 C Thermo Switch COOLING SYSTEM 4 17 When coolant temperature rises above 111 C 232 F the thermo switch detects this and turns on a warning light on dash Whenever you start the engine make sure the warning light is not on in started engine If the warning light comes on stop the engine immedi ately and check the cooling system for over heating Over heating can caused by Lack of coolant Clogging of cooling system Malfunction water pump or thermostat Check the coolant level and temperature frequently Thermo Switch Removal and Installation e Drain the coolant see Coolant Draining in this chapter e Disconnect the switch lead terminal B e Unscrew the thermo switch A and remove it e When installing the thermo switch apply silicone sealant to the threads and tighten the switch Torque Thermo Switch 28 N m 2 9 kgf m 21 ft Ib Sealant Kawasaki Bond Silicone Sealant 56019 120 Thermo Switch Inspection e Using a ohmmeter check to see that only the connections in the table have continuity x If the switch has an open or short repair it or replaced it with a new one Thermo Switch Connections eRising temperature From Off to On at 108 114 C 226 237 F Falling temperature From On to Off at 101 107 C 214 225 F ON Continuity OFF Infinit 4 18 COOLING SYSTEM Thermo Switch e Suspend the switch A in a container of coolant
2. CAMSHAFT CRANKSHAFT 7 11 Camshaft Tappet e Measure the inside diameter A of the camshaft bearing on the crankcase at several points This bearing is not replaceable Replace the crankcase if the inside diameter is more than the service limit Camshaft Bearing Inside Diameter Crankcase Service Limit 16 08 mm 0 6331 in e Measure the inside diameter A of the camshaft bearing on the crankcase cover at several points This bearing is not replaceable Replace the crankcase cover if the inside diameter is more than the service limit Camshaft Bearing Inside Diameter Crankcase Cover Service Limit 16 08 mm 0 6331 in 7 12 CAMSHAFT CRANKSHAFT Crankshaft Connecting Rod Connecting Rod Removal e Remove Piston see Engine Top End Chapter Connecting Rod Installation e Install Piston see Engine Top End chapter Crankshaft Removal e Set the engine on a clean surface while parts are being removed e Drain the oil see Lubrication System chapter e Remove Flywheel see Electrical System chapter Camshaft see Camshaft Tappet Removal Connecting Rod and Piston Assembly see Engine Top End chapter e Pull the crankshaft A out of the crankcase Tap gently with a wooden or plastic mallet if necessary to loosen the crankshaft Crankshaft Installation e Clean up the crankshaft and crankcase thoroughly espe cially at the bearing contact surfaces e Pack some amoun
3. Type Heavy duty type Pre Cleaner Primary element Two Stage Cleaner Secondary element Fuel Fuel Requirement Unleaded regular grade gasoline Fuel Pump Type Pulse diaphragm pump Governor Type Flyweight all speed governor 1 Idle speeds may vary depending on each equipment Refer to the equipment specification FUEL SYSTEM 3 9 Governor Link Mechanism Control Panel Assembly Removal e Remove Muffler see Muffler Exhaust Pipe Removal in the Engine Top End chapter Control Panel Mounting Bolts A e Remove the control panel assembly A while unhooking the governor spring B end loop at the governor arm e First clear the choke link rod end C from the carburetor and then remove the choke link from the choke lever KC04014BS2 C Control Panel Assembly Installation e Before installing the control panel assembly check to see that the choke lever A and engine speed control lever B move smoothly in all directions x If any part is worn or damaged replace the control panel assembly e After installation adjust the low idle speed and high idle speed to the specifications see Low Idle Speed and High Idle Speed Adjustment in the Periodic Maintenance chap ter Governor Arm Removal e Remove Control Panel Assembly e Loosen the clamp nut A and take off the governor arm B e Clear the throttle link rod C from the governor arm and choke lever 3 10 FUEL SYSTEM Governor
4. KE04012BS51 A Q Cylinder Head ENGINE TOP END 5 13 e Remove Bolts A Brackets B e Support the valve head in the combustion chamber with a suitable block e To remove the collets A push down the valve retainer B with thumbs and remove the collets e Remove the spring C and valve D e Remove the stem seals A NOTE Olt is not necessary to remove the stem seal unless it is being replaced OBottom spring retainer C can only be removed with stem seal OValve guide B is not replaceable do no remove it e Install the valve according to the following procedures OApply molybdenum disulfide grease to the valve stem to avoid damaging the stem seal OCheck to see that the valve moves smoothly up and down in the guide OCheck to see that the valve seats properly in the valve seat If it does not repair the valve seat e Valve installation is the reverse of removal e Install the cylinder head assembly see Cylinder Head Assembly Installation e Install the rocker arm according to the following proce dures OSet the flywheel at T D C of power stroke each cylinder see Cylinder Head Assembly Installation 5 14 ENGINE TOP END Cylinder Head Olnstall the brackets A on the cylinder head with two bolts B and tighten them Torque Rocker Arm Bracket Mounting Bolts 22 N m 2 2 kgf m 17 ft lb Olnstall the push rods see Push Rod Installation
5. 5 After use wash the cutter with washing oil and apply a thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter represent the following 45 Cutter angle A 24 5 Cutter diameter of cutter B Operating Procedures e Clean the seat area carefully e Recondition the valve seats with the valve seat cutters 45 32 and lap the valves e Check the seats for good contact all the way around with machinist s dye e Measure the seat width A If it is more than the STD width the seating surface should be refaced x lf the valve seating pattern is not correct repair the seat KE05005BS51 KE05002BS1 PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures e Coat the seat with machinist s dye e Fit a 45 cutter A to the holder and slide it into the valve guide OResurface the valve seat with a 45 cutter removing only enough material to produce a smooth and concentric seat CAUTION Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced Do not turn the cutter counterclockwise or drop it against the seat or it will be dulled e Use a 32 seat cutter A to narrow the seat width to the STD width OTurn the seat cutter one
6. Connecting Rod Small End Inside Diameter Service Limit 16 06 mm 0 6323 in Piston Diameter e Measure the outside diameter A of the piston 3 5 mm 0 14 in B up from the bottom of the piston at a right angle to the direction of the piston pin hole x If the measurement is less than the service limit replace the piston Piston Outside Diameter Service Limit 74 98 mm 2 952 in Cylinder Inside Diameter e Clean and measure the cylinder inside diameter OUse a dial bore gauge to measure front to back and side to side at the points shown below x If any of the cylinder bore measurements is greater than the service limit replace the cylinder with a new one 10 mm 0 39 in A 55 mm 2 17 in B Cylinder Inside Diameter Cylinder Inside Diameter Standard 75 18 75 20 mm 2 960 2 961 in Service Limit 75 30 mm 2 965 in Cylinder Bore Out of Round Service Limit 0 056 mm 0 0022 in KEO6057BS1 o KEO6O058BS1 o Muffler Exhaust Pipe ENGINE TOP END 5 25 Muffler Exhaust Pipe Removal A WARNING Do not touch the muffler when the muffler is still hot Wait until it cools down e Loosen the clamp nut A e Remove the bolts B on the muffler cover C and take off the muffler cover and the muffler D e Remove the bolts A on the muffler bracket B and take off the bracket e Unscrew the exhaust pipe flange nuts A and remove the exhaust pipe B with pipe cover C
7. Element Cleaning and Inspection e Refer to the Element Cleaning and Inspection in the Pe riodic Maintenance chapter Cleaner Body Removal e Remove the elements see Element Removal in this chapter e Remove the clamp A and take off the breather tube B and vent hose G e Loosen the nuts C and remove the solenoid valve lead terminal D e Unscrew the bolts E and remove the inlet pipe F FUEL SYSTEM 3 25 Air Cleaner Standard Type Cleaner Body Installation e Replace the inlet pipe gasket with new ones e Clean the mating surfaces of the carburetor and inlet pipe e Install the inlet pipe and connect the solenoid valve lead terminal e Tighten the mounting bolts and nuts Torque Carburetor and Inlet Pipe Mounting Bolts and Nuts 12 N m 1 2 kgf m 104 in Ib e Install the sleeve on the inlet pipe e Press in the sleeve A to the inlet pipe B fixing the groove C to the projection D as following e Connect the breather tube to the pipe at the inlet pipe and clip it with a clamp Kco6008BW2 C Housing Inspection e Refer to the Housing Inspection in the Periodic Mainte nance chapter 3 26 FUEL SYSTEM Air Cleaner Heavy Duty Type Element Removal e Unhook the two clips A and remove the cap B from the air cleaner housing e Remove Primary Element A Secondary Element B Element Installation e Slide the secondary element and primary element i
8. Regulator Resistance e Set the hand tester selector switch to the R x 100 Q po sition Special Tool Hand Tester 57001 1394 e Connect the test leads to the points shown on the chart and read the resistance x lf the resistance is not as specified replace the regulator NOTE OThis voltage regulator is an open type one Regulator A 6P Connector B Range R x 100 O z e D 0 45 ka 1 37 KQ NOTE OResistance value may vary with an individual meter KHO7023BS1 o 8 12 ELECTRICAL SYSTEM Ignition System The ignition system is the voltage interruption method which interrupts the primary current con ducted by turning the flywheel and generates the high secondary voltage and therefore this system is basically the same as the traditional system of mechanical contact parts As compared with the traditional mechanical parts and condenser a transistor in the igniter serves as an interrupter of the current This system is called TIC Transistor Ignition Control Electrical Circuit KH080238W2 C L1 Ignition Coil Primary L2 Ignition Coil Secondary R1 Resistance to regulate the base current of TR1 R2 Resistance to regulate the base current of TR2 SP Spark Plug SW Stop Switch TR1 Power Transistor TR2 Drive Transistor Ignition Theory of Operation 1 2 The revolution of the flywheel generates a volta
9. 10 mm 0 394 in 0 5 0 8 mm 0 020 0 031 in 28 mm 1 102 in 6 0 mm 0 24 in 0 2 mm 0 008 in 27 mm 1 06 in 0 4 mm 0 016 in ELECTRICAL SYSTEM 8 5 Special Tool Hand Tester 57001 1394 8 6 ELECTRICAL SYSTEM Wiring Diagram Color Code G orense CT KENTE Spark Plug 2 Ignition Ze Coil 2 Oil Pressure Switch BL R Coil Spark Plug 1 E N Ignition SA 1 lt gt PACKARD CONNECTOR TERM 2965867 BODY 2977044 49128 2752E Fuse 25A I Al mir Caburetor 1 D Starter o Zei Voltage Ragulator o N gt lt 2 Thermo A Switch T A Ge 5 l o Ki o o a E Ke lt ER JE o O dE gt o o FRE Sp A3 Ev i A E SE a o w z EAR o o ou e ll 0 4t 2 e e AV1 25 Ignition Switch OPortion surrounded by Z shows KHI procurement parts AVi 25 AV1 25 E dl Battery 12V KH04016BW4 C Precautions ELECTRICAL SYSTEM 8 7 There are a number of important precautions that are musts when servicing electrical systems Learn and ob serve all the rules below ODo not reverse the battery lead connections This will burn out the diodes in the electrical parts OAlways check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical system tes
10. 39 90 mm 1 571 in 40 04 mm 1 576 in 40 01 mm 1 575 in CAMSHAFT CRANKSHAFT 7 5 Sealant Kawasaki Bond 92104 1064 gt ST921064ST 7 6 CAMSHAFT CRANKSHAFT Crankcase Crankcase Cover Removal e Set the engine on a clean surface while parts are being removed e Drain the oil see Oil Change in the Periodic Maintenance chapter e Remove Muffler Assembly see Muffler Exhaust Pipe Removal in the Engine Top End chapter Air Cleaner and Related Parts see Element Removal and Cleaner Body Removal in the Fuel System chapter Carburetor Assembly see Carburetor Removal in the Fuel System chapter Control Panel see Control Panel Assembly Removal in the Fuel System chapter Radiator see Radiator Removal in the Cooling System chapter Radiator Hoses and Bypass Tube Water Pump see Water Pump Removal in the Cooling System chapter Cooling Fan and Brackets see Cooling Fan Removal in the Cooling System chapter Cylinder Head Assemblies see Cylinder Head Assembly Removal in the Engine Top End chapter Inlet Manifold see Inlet Manifold Removal in the Fuel Sys tem chapter Flywheel see Flywheel Stator Coil Removal in the Elec trical System chapter Stator Coil see Flywheel Stator Coil Removal in the Electrical System chapter Ignition Coils see Ignition Coil Removal in the Electrical System chapter Starter Motor see Starter Motor Removal in the Electrical System chapter e Unscrew the mounting
11. The valve opens automatically when the switch key is turned to the Run position Low ldle Speed Adjustment e Refer to the Low Idle Speed Adjustment in the Periodic Maintenance chapter High Idle Speed Adjustment e Refer to the High Idle Speed Adjustment in the Periodic Maintenance chapter High Altitude Operation At high altitude the standard carburetor air fuel mixture will be excessively rich Performance will decrease and fuel consumption will increase High altitude performance can be improved by installing a smaller diameter main jet in the carburetor and correct idle speed Main jet R A Main jet L B NOTE OThe main jet high altitude kits are available if the equip ment is to be used in the high altitudes The main jet numbers are stamped on ends of the main jets High Altitude Main Jet Altitude Main Jet No FD680V FD731V 0 1 000 m 0 3 000 ft R 130 R 120 L 128 8 L 115 1 000 2 000 m 3 000 6 000 ft R 127 5 R 117 5 L 126 3 L 112 5 2 000 m 6 000 ft and higher R 125 R 115 L 123 8 L 110 730P028351 KC05B043 P Carburetor FUEL SYSTEM 3 15 Main Jet Replacement e Place the engine equipment on a level surface e Close the fuel shut off valve in the equipment e Drain the fuel in the carburetor completely by unscrewing the drain screw A at the bottom of the float chamber e Remove the carburetor s
12. E wem Kawasaki FD731V 4 stroke liquid cooled v twin gasoline engine Service Manual 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 Quick Reference Guide General Information Periodic Maintenance Fuel System Cooling System Engine Top End Lubrication System Camshaft Crankshaft Electrical System Troubleshooting FD680V FD731V Kawasaki 4 stroke liquid cooled v twin gasoline engine Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Division Consumer Products amp Machinery Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously All information contained in this publication
13. Olnsert the collar B into the rocker arm hole E so that the groove C of the collar face toward upside D then set them on the brackets A Olnsert the washer F onto bolt G and insert the bolt G into the hole at the rightside H of the bracket A and through the collar installed with rocker arm Olnstall the nut I onto the bolt G and tighten the nut temporarily OPosition the push rod end on to rocker arm dent Cylinder Head Cleaning e Refer to the Cylinder Head Cleaning in the Periodic Main tenance chapter Cylinder Head Inspection e Lay a straightedge A across the mating surface of the head at several different points and measure warp by inserting a thickness gauge B between the straightedge and head If warp exceeds the service limit repair the mating sur face Replace the cylinder head if the mating surface is badly damaged Cylinder Head Warp Service Limit 0 03 mm 0 001 in e Check the cylinder head for cracks or other damage e Cracks not visible to the eye may be detected by coating the suspected area with mixture of 25 kerosene and 75 light engine oil e Wipe the area dry and immediately apply a coating of zinc oxide dissolved in wood alcohol Ifa cracks is present the coating will become discolored at the defective area e f a cracks is present in the cylinder head replace it e Inspect the mating surface for burrs and nicks Cylinder Head ENGINE TOP END 5 1
14. e Tighten the cap bolts temporarily NOTE OBefore tightening the cap bolts to the specified torque make sure that the sliding surface between the connect ing rods moves freely e Tighten the cap bolts to the specified torgue Torque Connecting Rod Big End Cap Bolts 9 8 N m 1 0 kgf m 87 mb e Check the connecting rods move freely after tightening the bolts x If the connecting rods do not operate freely remove the bolts and adjust them e Install Camshaft see Camshaft Crankshaft chapter Crankcase Cover see Camshaft Crankshaft chapter e Install the other removed parts Piston Cylinder Seizure e In case of seizure remove the piston e Visually inspect the cylinder and piston damage lf there is only light damage smooth the position with 400 emery cloth Remove the small aluminum deposits from the cylinder with 400 emery cloth or light honing x If the damage is severe replace the cylinder and pistons KEO06055BS2 C 5 22 ENGINE TOP END Cylinder Piston Piston Cleaning e Remove the piston and piston rings see Piston Re moval CAUTION Never clean the piston head with the engine assem bled Carbon particles will fall between the piston and cylinder and damage the crankshaft bearings e Scrape the carbon off A the piston head e Use the scraping tools carefully Do not gouge the piston head To avoid gouging use scrapers that are made of a material that will not cause dama
15. 4 10 COOLING SYSTEM Water Pump Water Pump Removal e Loosen the tube clamp A and pull off the coolant by pass tube B Water Pump Cover C e Unscrew the water pump mounting bolts in the order shown and remove the water pump cover and gasket NOTE ONote the position of different length of bolts so they can be installed in their original positions Bolt Dimensions Bolts M8 L 100 mm 3 9 in A Bolts M8 L 35 mm 1 4 in B e Unscrew the impeller bolt A and remove the impeller B OThe impeller bolt has left hand threads Water Pump Installation e Chip the old gasket off the mating surfaces of the crankcase cover and pump cover e Put a new gasket on the pump cover e Install the impeller and tighten the impeller bolt to the specified torque OThe impeller bolt has left hand threads Torque Impeller Bolt 10 N m 1 0 kgf m 87 in Ib Water Pump COOLING SYSTEM 4 11 e Install the mounting bolts and tighten them in the order shown Torque Water Pump Cover Mounting Bolts M6 10 N m 1 0 kgf m 87 in Ib Water Pump Cover Mounting Bolts M8 22 N m 2 2 kgf m 16 ft lb e Note the position of different length of bolts Pumps Parts Inspection e Clean all parts except plastic and rubber parts in a bath of high flash point solvent and dry them compressed air Clean non metal parts with detergent and water and dry them e Inspect the pump cover for damage Mating surfaces
16. Spark Plug Caps Stop Switch Lead Connector A Bolts B Ignition Coil C Ignition Coil Installation e Install ignition coil on crankcase and tighten bolt 1 first then tightening bolt 2 While tightening bolts adjust the air gap B between the legs of ignition coil and the fly wheel C to the specified gap value as shown NOTE OThe ignition coils are not identical The ignition coil for 1 cylinder electric starter side is identified by 1 on its S surface and the other by 2 Install the ignition coils on kuosoz4esi the cylinders so that the each identical number matches the cylinder number Identical Number D Ignition Coil Air Gap Standard 0 25 0 40 mm 0 010 0 016 in Torque Ignition Coil Mounting Bolts 3 4 N m 0 35 kgf m 30 in Ib NOTE OAbove procedure must be used to insure proper coil air gap is not too large 8 14 ELECTRICAL SYSTEM Ignition System Ignition Coil Inspection e Remove the ignition coils see Ignition Coil Removal in this chapter e Measure the primary winding resistance as follows OSet the hand tester to the R x 1 Q range Special Tool Hand Tester 57001 1394 OMake the measurements shown in the table Ignition Coil Primary Winding Resistance A B A 16 240 B ei CAUTION Use only Tester 57001 1394 with new battery at room temperature for this test A tester other than the Kawasaki Hand Tester sho
17. Special Tools Oil Pressure Gauge 10 kgf cm 57001 164 Oil Pressure Gauge Adapter PT 1 8 57001 1033 e Run the engine and allow warm up completely e Run the engine at fast idle speed and read the oil pressure gauge e Stop the engine e Remove the oil pressure gauge and adapter e Apply silicone sealant to the taper threads of the pressure switch and install the switch Sealant Kawasaki Bond Silicone Sealant 56019 120 Torque Oil Pressure Switch 9 8 N m 1 0 kgf m 87 in Ib x If the oil pressure is below the specification inspect the oil pump and relief valve x If the oil pump and relief valve are not at fault inspect the rest of the lubrication system Oil Pressure 294 686 kPa 3 0 7 0 kgf cm 42 6 99 5 psi Measurement Condition Engine Oil Temperature 50 60 C Oil Pressure Switch Screw PT 1 8 pipe thread Pressurized Lubrication System LUBRICATION SYSTEM 6 9 Oil Pressure Switch Inspection When the oil pressure falls below 98 kPa 14 2 psi the oil pressure switch activates the oil warning light to alert the operator or lubricating problem e To check the oil warning system insert the switch key into the OFF position of the engine switch then turn it to the RUN position The warning light must be illuminated e Whenever start the engine make sure the warning light is not on in started engine x If the warning light comes on stop the engine immediately and
18. Use a penetrating oil if necessary to break threads loose e Remove the gaskets e Unscrew the nuts D separate the exhaust pipe and pipe cover e Do not use unnecessary force on the exhaust pipes when removing the muffler assembly or they could become damaged or destroyed Muffler Exhaust Pipe Installation e Clean the exhaust pipe flanges to the exhaust port gasket surfaces and install a new gaskets each time the muffler installed e Install the gasket e To prevent mis threading finger tight the flange nuts first Next tighten the nuts e Tighten the exhaust pipe flange nuts Torque Exhaust Pipe Flange Nuts 20 N m 2 0 kgf m 15 ft lb e Install the muffler e After installation thoroughly warm up the engine wait un til the engine cools down and retighten the bolts and nuts Inspection e Inspect the exhaust pipe or muffler for dents cracks rust and holes x lf the exhaust pipe or muffler is damaged it should be replaced for best performance and least noise e Check the muffler for distortion and or loose internal com ponents Loss of power could develop if the muffler loose the internal components restricting the exhaust flow e Check for breaks in the seams and check weld at the junction of the exhaust pipes and muffler e Tap the muffler with a plastic hammer to decarbonize LUBRICATION SYSTEM 6 1 Lubrication System Table of Contents leie e WEE 6 2 Engine Qil lOW EECHER 6 4 Sp
19. 6 82010 EE 4 7 Coolant Deterioration an a a a a SS 4 7 Coolant Level INSpectiON ocococccnnncnnncnnnnnnnnnnnnononononnnonononnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnennnnnss 4 7 Coolant Ke TU e DEE 4 7 elei Ei L ln e EE 4 8 PUP BISCO A EE 4 8 Visual Leak Inspection e cceeccee cece cece cece eeee cette eee eeeeeeeeeeeeeeeeeeeeeeeeeeneeeeeeeeeeegeeeeeeeneeeneeeees 4 8 Cooling System Pressure Testing iio it sevens ddan dee en ena 4 8 e CT Le WEEN 4 9 Water PUMP EE 4 10 Water PUMP Removal naene ne 4 10 Water Pump Installati0D ooooooooooonnnonncnonooonoconaconono non nono nnnnnnnnnnnnnnnno non nono e ia n 4 10 Pumps Parts Inspection tin did add tii cas 4 11 A suite Ae EEEE E E SEENEN EEN REENEN EEN 4 12 Radiator Removal miii ENER aden een its 4 12 Radiator Installation is eaa e e aaee a e a E aa ina 4 12 Radiator INSPeCton s oi bande 4 12 Radiator Cap Inspection cceecceeceeecceeeeeeeeeeeeeeeeeeeeeeeeneeeeeeeedeeeeseeeeeeeeeeeeeeeeeeeeeeeseeeneeess 4 13 Radiator Hose Inspection ee aia 4 14 Radiator Hose Installation Notes ccccceeceeeeeee cece eee e eee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 4 14 Cooling AUN eS seit Se A a ee a ec dae te AAA he FAA A eee 4 15 Coolirig Fan Ee TEE 4 15 Cooling Fan Installation A O A ei eaa 4 15 Co ling Fam Ee e 4 15 Rule EEN 4 16 Thermostat Removal and Installation oooonooonoonnnnncononoconcnoncnoncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnns 4 16 The
20. 6 PreGauUtlOnS ivicessidsvaissvaviesev Nee AA ENEE Neen deed terse 8 7 Charging Bean ol EE EE 8 8 Flywheel Stator Coil Removal cece ce cee cece cece eect eects eeeeeeeeegeeeeeeeeneeedeeeeeeeeeeeeeeeeeeeees 8 8 Flywheel Stator Coil Installation ccecc cece cece cece cece cece reee cece tees eee sense eeeeeeeeeeeeeeeseeeeeeeeeeees 8 8 Charging System Operational Inspection eee eeeceeeeeeeeeeeeee tent teeter eeeeeneaaeeeeeeeeeeeeeaaaees 8 9 Stator Coil Resistance ts EE at EE 8 9 Unregulated Stator Output EE 8 10 Reguiator Removal sieneen e A a RA aula ee ia 8 10 Regul tor Installati EE 8 10 Regulator RES ISVS EE 8 11 Ignition KE EE 8 12 ege Be TR EE 8 13 Ignition Coil Install WEE 8 13 e ten SSS E 8 14 Ignition Coil MMSPSCHON EE EE 8 14 Spark Plug Cleaning and INSPeCtiOn ccccseeeecccceeeeeeeececeeeeceeeeeseeeeeeeeenseeeeeeeseeseneeeee 8 14 Spark Plug Gap INSPOCHOM sci sidccehscucslaucceticancasattacdscecbcaceuegcstuudlarsalvvanliaateashdoegeunasuntetecas 8 14 Electric Starter Systainer tinc 8 15 Starter Motor REMOVAL seeen to ariete 8 15 Starter Motor Installaton 8 15 Starter Solenoid and Circuit EE 8 15 Starter Motor E 8 16 Starter Motor DisassembDlV ii A a ae ek 8 17 Starter Motor Assembly Notes catan ita 8 18 Starter Motor Brush Inspection s sssssessseeeseneseeereeereertterttrttrttrrrtrtrttrrrtrittrrtttrtrrrtrrrtttttrent 8 19 Brush Spring RI ee BEE 8 19 NES 8 19 Yoke Assembly Inspection a
21. B Plug Gap C Side Electrode D GP10012351 e Measure the gap with a wire type thickness gauge x lf the gap is incorrect carefully bend the side electrode with a suitable tool to obtain the correct gap Spark Plug Gap Standard 0 75 mm 0 30 in FUEL SYSTEM 3 1 Fuel System Table of Contents Exploded View 3 2 Carburetor Inspection Specifications oooooonccininininicccicnns 3 8 Fuel Shut Off Solenoid Valve Governor Link Mechanism 3 9 TeSt ter eeie eft e e nantes 3 20 Control Panel Assembly Removal 3 9 Inlet Manifold eseeeeeeeeeenee 3 21 Control Panel Assembly Inlet Manifold Removal 3 21 Installation oooooocccccccncco 3 9 Inlet Manifold Installation 3 21 Governor Arm Removal 3 9 Inlet Manifold Inspection 3 21 Governor Assembly Removal 3 10 FUE PUMP ENEE e 3 22 Governor Assembly Installation 3 11 Fuel Pump Inspection 3 22 Governor Assembly Inspection 3 11 Fuller i 3 23 Governor Shaft Removal 3 11 Fuel Filter Inspection 3 23 Governor Shaft Installation 3 12 Air Cleaner Standard Type 3 24 Carburetor ococcccccccconicnnnninnneninenineninen 3 13 Element Hemoval 3 24 Fuel and Air FIOW assaanaaeeeaeaaaaaen 3 13 Element Installaton 3 24 Fuel Shut Off Solenoid Valve 3
22. Crankshaft Main Journal Weal occoocconcconcconcnnncnnncnnncnncnoncnnnononcnonononenoneronnnnnannncnnnannncnnnes 7 14 7 2 CAMSHAFT CRANKSHAFT Exploded View CAMSHAFT CRANKSHAFT 7 3 Exploded View Fastener Jorane Remarks kgf m ft Ib 1 Crankcase Cover Bolts M8 22 2 2 17 S 2 Connecting Rod Big End Cap Bolts 9 8 1 0 87 in lb O G Apply grease O Apply engine oil R Replacement Parts S Follow the specific tightening sequence SS Apply silicone sealant 7 4 CAMSHAFT CRANKSHAFT Specifications Item Service Limit Camshaft Tappet Cam Lobe Height Inlet Exhaust Camshaft Journal Diameter PTO Side Flywheel Side Camshaft Bearing Inside Diameter Crankcase Crankcase Cover 41 45 mm 1 6319 in 15 99 mm 0 6295 in 15 99 mm 0 6295 in 16 08 mm 0 6331 in 16 08 mm 0 6331 in Crankshaft Connecting Rod Connecting Rod Bend Connecting Rod Twist Connecting Rod Big End Width Crankpin Width Connecting Rod Big End Inside Diameter Crankpin Outside Diameter Crankshaft Runout Crankshaft Journal Diameter PTO Side Flywheel Side Crankcase PTO Shaft Bearing Inside Diameter Crankcase Cover Crankcase Crankshaft Journal Bearing Inside Diameter 0 2 100 mm 0 008 3 94 in 0 2 100 mm 0 008 3 94 in 20 2 mm 0 795 in 45 0 mm 1 772 in 40 05 mm 1 577 in 39 95 mm 1 573 in TIR 0 05 mm 0 002 in 39 90 mm 1 571 in
23. E e EE 5 18 Piston Installation dica data 5 19 e Defense 5 21 Pist n GEA EE 5 22 Piston Ring and Ring Groove Wear 2 c eceecececceee eee eeeeedeneeeeeeseeeneseneeneesseeeeseneneenensneeee 5 22 Pist n Ringi NG Gap EE 5 23 Piston Pin Piston Pin Hole and Connecting Rod Wear 5 23 Piston Dia UE EE 5 24 Cylinder Inside Ria TEE 5 24 Muffler Exhaust Pip gt iii de dior Siena a Lae eee ace a ees 5 25 Muffler Exhaust Pipe Hemoval n nEn EEEE EEEE EEEE E EEEE EEEE n EEEn EE EEEE 5 25 Muffler Exhaust Pipe Installaton 5 25 ANEA EE E A A A EAT AT 5 25 5 2 ENGINE TOP END Exploded View Gm O D 4 ez O o eg ENGINE TOP END 5 3 Fastener Torque N m kgf m ft Ib Exploded View Rocker Arm Bracket Mounting Bolts 22 2 2 17 Valve Clearance Adjusting Nuts 11 1 1 96 in lb 3 Connecting Rod Big End Cap Bolts 9 8 1 0 87 in lb O M Apply molybdenum disulfide grease O Apply engine oil R Replacement Parts 5 4 ENGINE TOP END Exploded View Exploded View ENGINE TOP END 5 5 Fastener Exhaust Pipe Flange Nuts Torque kgf m ft Ib Cylinder Head Bolts New Cylinder Head Bolts Reuse N m 2 0 x 3 3 Muffler Bracket Bolts R Replacement Parts S Follow the specific tightening sequence 2 5 18 2 0 15 5 6 ENGINE TOP END Specifications Item Service Limit Cylinder Head Cylinder c
24. Link Mechanism e Install the governor arm A onto the governor shaft B temporarily e Install the control panel assembly and connect the gov ernor arm with the governor spring C as shown Longer Side D e Install the throttle link rod E as shown Carburetor Side of the Link Rod F e Be sure the link spring G around the throttle link rod E is in place as shown and that it pulls the governor arm and throttle lever H each other e Loosen the clamp nut I on the governor arm enough to move the governor shaft e Turn top end of the governor arm counterclockwise to fully open the carburetor throttle valve and tighten the clamp nut to the specified torque Torque Governor Arm Clamp Nut 8 N m 0 8 kgf m 69 in Ib e Be sure the governor arm B is installed as shown Governor Shaft A Crankcase C Approx 8 5 mm 0 33 in D Governor Assembly Removal e Remove Crankcase Cover see Crankcase Cover Removal in the Camshaft Crankshaft chapter e Remove the governor assembly A with the sleeve B by prying the gear with two proper size screw drivers NOTE OTo avoid damage to the surface of crankcase cover use a suitable soft mats C as shown CAUTION Do not remove the governor assembly unless it is necessary Once it has been removed it must be replaced e Remove the thrust washer KCO4015BS2 C Governor Link Mechanism FUEL SYSTEM 3 11 Governor Assembly
25. Olf the engine oil type and make are unknown use any brand of the specified oil to top up the level in preference to running the engine with the oil level low Then at your earliest convenience change the oil completely KFOSBOIA P PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures Oil Change e Change oil after first 8 hours of operation Thereafter change oil every 100 hours e Start and warm up the engine so the oil will drain easily Stop the engine e Place the engine on a level surface e Place a suitable container under the engine e Remove the drain plug A and drain the oil A WARNING Be careful with not oil being drained If may be hot enough to burn you severely e Check the gasket B at the drain plug for damage Re place the gasket with a new one e Install the drain plug with the gasket and tighten it Torque Oil Drain Plugs 6 9 N m 0 70 kgf m 61 in Ib e Remove the oil filler cap and pour in the specified type lt Ambient Temper ature gt and amount of oil 200 100 OC 10C 20C 300 40 C Engine Oil Grade API Service Classification SF SG SH or SJ Class SAE10W 30_ SAE10W 40 Viscosity SAE40 SAE30 SAE10W 30 SAE10W 40 SZEN OF SAEs ze Sea Capacity 2 0 L 2 1 US qt AF Ar 32 F ar er ar 104F When filter is not removed 2 3 L 2 4 US qt When filter is removed Level Between ADD and FULL level lines NOTE OSome
26. Place a new gaskets on each mating surface and install the manifold e Tighten the mounting bolts following the tightening se quence Torque Inlet Manifold Mounting Bolts 6 N m 0 6 kgf m 53 in Ib Inlet Manifold Inspection e Visually inspect the coolant passage in the manifold for deposits or corrosion in layers inside the passage clean the passage if necessary e An improperly installed gaskets can cause coolant leak age and air drawn into the induction passage Check the gaskets for correct installation NOTE OSmall coolant leaks appear only as a rust corrosion or stain e Inspect the inlet manifold for cracks or porous casting e Cracks not visible to the eye may be detected by coating the suspected area with mixture of 25 kerosene and 75 light engine oil e Wipe the area dry and immediately apply a coating of zinc oxide dissolved in wood alcohol If a cracks is present the coating will become discolored at the defective area x lf a crack is present in the inlet manifold replace it e Inspect the gasket surfaces for burrs and nicks 3 22 FUEL SYSTEM Fuel Pump The fuel pump cannot be disassembled if any damage for the pump is noticed replace it with a new one Fuel Pump Inspection e Check the vent holes A and filter B for plugging or clog ging x If vent hole and filter are plugged or clogged remove the foreign matter from them Fuel Flow Test A WARNING Gasoline is
27. Removal Instal lation e Measure the thickness of the valve head x If the valve head thickness valve margin A is less than the service limit replace the valve Valve Head Thickness Service Limit Inlet Exhaust 0 35 mm 0 014 in Valve Stem Runout e Support the valve in V blocks at each end of the stem e Position a dial gauge perpendicular to the stem e Turn the valve and read the variation on the dial gauge x If the stem runout is greater than service limit replace the valve Valve Stem Bend Service Limit Inlet Exhaust 0 05 mm 0 002 in Valve Stem Diameter e Measure the diameter of the valve stem A in two di rections at right angles at four different positions on the stem lf any single measurement is less than the service limit replace the valve Valve Stem Diameter Service Limit Inlet Exhaust 6 94 mm 0 2730 in KE05007B51 E 6E03010751 KEG5008BS1 Valves ENGINE TOP END 5 17 Valve Guide Inside Diameter e Use a small bore gauge or a micrometer to measure the inside diameter A of the valve guide a three places down the length of the guide x If the measurement is more than the service limit replace the cylinder head with a new one Valve Guide Inside Diameter Service Limit Inlet Exhaust 7 08 mm 0 279 in Valve Spring Inspection e Inspect the valve spring for pitting cracks rusting and burrs Replace the
28. SYsteM coociniosin ars Spark Plug Cleaning and Gap Inspection Maintenance of Contents 2 2 2 4 2 6 2 7 2 8 2 8 2 8 2 9 2 9 2 10 2 11 2 11 2 11 2 11 2 12 2 12 2 13 2 13 2 16 2 16 2 17 2 17 2 18 2 18 2 2 PERIODIC MAINTENANCE Periodic Maintenance Chart To ensure satisfactory operation over an extended period of time any engine requires normal main tenance regular intervals The Periodic Maintenance Chart below shows periodic inspection and maintenance items and suitable intervals The bullet mark e designates that the corresponding item should be performed at that interval Some adjustments require the use of special tools or other equipment An electronic tachometer will facilitate setting idle and running speeds INTERVAL Every Every Every Every Every Every Daily 200 250 300 400 500 OPERATION hr hr hr hr hr Check and add engine oil e Check coolant level in the overflow reservoir Check for loose or lost bolts nuts and screws Check for fuel and oil leakage Check battery electrolyte level Check and clean radiator screen Tighten bolts nuts and screws Clean air cleaner foam element Standard air cleaner model 1 Clean air cleaner paper element Standard air cleaner model 1 Change engine oil Clean and re gap spark plugs Inspect radiator and hoses leakage Change oil filter Replace air cleaner paper element Standard a
29. a 0 15 mm 0 006 in thickness gauge A between the rocker arm and valve stem and turn the adjusting bolt until the thickness gauge begin to bind between the rocker arm and valve stem end Use a sweeping motion with the thickness gauge while making this adjustment e Holding the adjusting bolt with a spanner tighten the nut to the specified torque Torque Valve Clearance Adjusting Nuts 11 N m 1 1 kgf m 96 in Ib CAUTION KE04021BS1 PERIODIC MAINTENANCE 2 13 Periodic Maintenance Procedures Valve Seat Inspection e Remove the valve see Valve Mechanism Removal Instal lation in the Engine Top End chapter e Inspect the valve seats for damage x lf the seats are warped or distorted beyond recondition ing replace the cylinder head e Pitted or worn valve seats can be refaced Lap the valves to the seats after refacing e Coat the valve seat with machinist s dye e Push the valve into the guide e Rotate the valve against the seat with a lapper e Pull the valve out and check the seating pattern on the valve head It must be the correct width A and even all the way around KE05004BS1 NOTE OThe valve stem and guide must be in good condition or this check will not be valid Good A Too Wide B Too Narrow C Uneven D x lf the valve seating pattern is not correct repair the seat Valve Seating Surface Width STD Inlet 0 8 1 4 mm 0 031 0 055 in E
30. bolts in the order shown 1 7 and pull the crankcase cover from the crankcase OThere are two knock pins on the crankcase mating sur face A wooden or plastic mallet may be used to gently tap loose the crankcase cover Crankcase Cover Installation e Before fitting the cover onto the crankcase note the fol lowing e Chip off the old gasket from the mating surfaces of the crankcase and cover e Using compressed air blow out the oil passage in the crankcase cover e With a high flash point solvent clean off the mating sur faces of the crankcase and cover and wipe dry CAMSHAFT CRANKSHAFT 7 7 Crankcase A WARNING Clean the crankcase and cover in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean parts A fire or explosion could result e Be sure to replace any oil seal removed with a new one Olnstall the oil seal so that the marks A face out OPack some amount of a high temperature grease B into the space between the seal lip C and dust lip D Press in the new oil seal 0 0 5 mm 0 0 02 in E below the crankcase cover surface F using a press or suitable tools until it is flush with flange surface Do not damage the seal lips KG04030BS1 o Crankcase installation e Check to see that the crankcase dowel pins A are i
31. carburetor YES4 NO7 3 r NO gt Faulty spark plug Replace Faulty ignition coil Replace m ES gt incorrect air gap Faulty flywheel Correct Replace No fuel in the tank Entry of dust or air into fuel pipe or filter Plugged air hole in tank cap and fuel pump Plugged fuel line r Add E Clean Clean Clean Excessive use of choke Plugged air cleaner eToo high fuel level in float bowl H Remove the plug and turn the crankshaft without loading Clean H Adjust Are spark produced when rr YES gt spark plug is replaced NO y Are sparks produced m YES gt when ignition coil is replaced NO gt Make starting attempts NO gt a number of times and then remove spark plug and observe electrodes Are they wet YES gt ET Check for fuel line Check for plugged air passage Check float level Check carb setting plugged Worn piston piston rings Stuck piston rings Worn cyl bore lnsufficient cyl head tightening Faulty contact of valve seat Plunge up by valve Warped cyl head Broken valve spring Stuck valve Burned head gasket Replace H Clean or replace Bore or replace Retighten Lap Adjust valve clearance H Replace Replace H Clean or replace H Replac
32. check the oil level e When starting the engine note the warning light on dash carefully x lf the warning light is on in the started engine in spite of adequate oil level check the lead from the pressure switch to the warning light for short circuit and or check the pressure switch and replace damaged part x lf the light is not on at the moment of the engine switch operation check all leads of the warning light circuit or bulb and replace damaged parts 6 10 LUBRICATION SYSTEM Oil Pump and Relief Valve Oil Pump Relief Valve Removal e Remove the crankcase cover see Crankcase Cover Re moval in the Camshaft Crankshaft chapter e Unscrew the mounting bolts and remove the oil pump parts assembly pump gear pump cover plate pump shaft pins and rotors e Take off the relief valve spring and ball e Disassemble the pump parts assembly Pin A Pump Gear B Mounting Bolts C Outer Rotor D Inner Rotor E Pump Shaft F Relief Valve Ball G Spring H Pump Cover Plate I 6 mm DIA Hole J Oil Pump Relief Valve Installation e Fill the rotor housing with engine oil for initial lubrication e Install the relief valve ball and spring in position then in stall the pump parts assembly in the crankcase cover NOTE OWhen installing the pump parts assembly align the 6 mm DIA hole A on the cover plate with center of the relief valve e Apply a non permanent locking agent to the threads of the mounting bo
33. governor shaft into the crankcase and washer A e Fit the circlip B securely into the groove of governor shaft C as shown e Check that the governor shaft moves freely in its operating range NOTE Olf the oil seal is removed reinstall it after the shaft is installed KC04018B51 Carburetor FUEL SYSTEM 3 13 Fuel and Air Flow The main system of the carburetor consists of the main jet A main nozzle B and the main air passage main air jet C The main system meters fuel to the engine during moderate to heavy load conditions Fuel flows through the main jet and into the bleed pipe D where it is joined by air from the main air passage main air jet The resulting mix ture flows out the end of the main nozzle into the carburetor bore where it is atomized by the high speed air flow and carried into the engine The pilot system includes the pilot jet E pilot screw idle mixture screw C pilot air jet D pilot outlet F and the by pass holes G The pilot system meters the fuel air mixture while the engine is idling and running under a light lead Un der these conditions there is very little air flow through the carburetor bore so little that it is not enough to draw fuel through the main system of the carburetor and atomize it Instead the fuel is drawn through the pilot system since the nearly closed throttle valve A causes high speed air flow past the pilot outlet and bypass hol
34. groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Piston Ring End Gap e Remove the piston rings e Push each ring one at a time in the cylinder bore to a point close to the bottom of the cylinder bore OUse the piston to push it in to be sure it is square e Measure the gap B between the ends of the ring A with a thickness gauge x If the end gap of any ring is greater than the service limit replace the entire set of rings KEG6010BS1 Piston Ring End Gap Service Limit Top Second 0 7 mm 0 03 in Oil 1 0 mm 0 04 in Piston Pin Piston Pin Hole and Connecting Rod Wear e Remove the piston pin e Measure the diameter of the piston pin with a micrometer at several points x lf the outside diameter is less than service limit replace the piston pin Piston Pin Outside Diameter Service Limit 15 96 mm 0 628 in e Measure the inside diameter A of the piston pin hole at several points on both side Use a dial bore gauge Xx If the inside diameter is more than the service limit re place the piston Piston Pin Hole Inside Diameter Service Limit 16 09 mm 0 6335 in 5 24 ENGINE TOP END Cylinder Piston e Measure the inside diameter A of the small end of the connecting rod at several points Use a dial bore gauge Xx lf the inside diameter is more than the service limit re place the connecting rod
35. increase in oil consumption may be expected when a multi grade engine oil 10W 30 10W 40 5W 20 is used Check the oil level frequently Oil Filter Replacement e Using a strap wrench or oil filter wrench A remove the oil filter B Special Tool Oil Filter Wrench 57001 1249 OWhen unscrewing the oil filter place a suitable container beneath the oil filter to receive oil from the oil filter and oil passages in the engine Turn the filter counterclockwise to remove it 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Apply a thin coat of grease to the seal A e Install a new filter OTurn the filter until the seal contacts mounting surface B of the engine Then turn the filter BY HAND S 3 4 turn more e Run the engine at slow idle speed 2 minutes Check for leaks around the engine e Stop the engine Check the oil level see Oil Level Inspec tion in this chapter Electrical System Spark Plug Cleaning and Gap Inspection e Remove the spark plug see Spark Plug Removal in the Electrical System chapter x If the plug is oily or has carbon build up on it clean the PEIES WSS S plug using a high flash point solvent and a wire brush or _ A other suitable tool ENS x lf the spark plug electrodes are corroded or damaged z or if the insulator is cracked replace the plug Use the N standard spark plug or its equivalent Insulator A Center Electrode
36. 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 2004 Kawasaki Heavy Industries Ltd First Edition 1 Nov 30 2004 K ABDC AC ATDC BBDC BDC BTDC C DC F ft P 3 LIST OF ABBREVIATIONS 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 psi rpm TDC TIR Soe E pound s meter s minute s newton s pascal s horsepower pound s per square inch revolution revolution s per minute top dead center total indicator reading volt s watt s ohm s Read OWNER S MANUAL before operating EMISSION CONTROL INFORMATION To protect the environment in which we live Kawasaki has incorporated crankcase emission 1 and exhaust emission 2 control systems in compliance with applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board 1 Crankcase Emission Control System A sealed type crankcase emission control system is used to eliminate blow by gasses The blow by gasses are led to a breather chamber through the crankcase and from there to the air cleane
37. keep your hands clear of the moving parts e Move the throttle lever on dash in the high idle position and leave it there e Loosen the M6 control panel mounting bolts A enough to move the control panel assembly B e Carefully move the control panel assembly up or down to obtain the specified high idle speed High Idle Speed 3 600 rpm r min e Tighten the M6 mounting bolts CAUTION Be sure to make the idle and fast idle speeds re spectively correspond to those of the equipment DOIT Al d Ka SE KC04037BS1 o Periodic Maintenance Procedures PERIODIC MAINTENANCE 2 9 Low Idle Speed Adjustment e Disconnect all possible external loads from the engine e Start the engine and warm it up thoroughly A WARNING Always keep your hands clear of the moving parts e Move the throttle lever on dash to the idle position e Hold the throttle lever A on the carburetor in closed po sition turn the governer arm B clockwise all the way and adjust the low idle speed screw C until the engine idles at specified speed Idle Speed Carburetor idle rpm 1 450 rpm r min e Release the throttle lever and adjust the low idle speed set screw D on the control plate to obtain the specified governed low idle speed Low Idle Speed Governed idle rpm 1 550 rpm r min Fuel System Cleanliness Inspection A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions
38. pilot screw limiter on the carburetor body so that it can be installed and set to its original position later ORemove the limiter Be careful not to turn pilot screw at this point OTurn the pilot screw clockwise and count the number of turns until screw is gently seated in the pilot passage Record the number of turns needed to closed the screw OTurn out the pilot screw to replace it with a new one Olnstall the new pilot screw until the screw is gently seated Then open the screw the same number of turns as recorded prior to removal OAlign the limiter with the mark on the carburetor body to install taking care not to turn the pilot screw e Install the choke valve on the shaft as the out side mark of it facing out side e Drive in the float pin so that the pin extends the same distance on both side of the float hinge bracket e The fuel inlet valve seat is pressed into the carburetor body and is not replaceable e When assembling the carburetor parts which are attached to the carburetor with the recommended tightening torque of a bolts and screws see Exploded View KCO05064BS2 C 3 18 FUEL SYSTEM Carburetor Carburetor Cleaning A WARNING Clean the carburetor in a well ventilated area and take care that there is no spark or flame anywhere near the working area this include any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solv
39. read close 0 Q the yoke assembly is faulty Replace it Negative Brush to Ground Resistance Close 0 Q Pinion Clutch Inspection e Remove the pinion clutch e Turn the pinion gear by hand The pinion gear should turn counterclockwise freely but should not turn clockwise x lf the pinion clutch dose not operate as it should or if it makes noise replace the pinion clutch KHO9015B S TROUBLESHOOTING 9 1 Troubleshooting Table of Contents Engine Troubleshooting Guide eege EE AE e 9 2 Starter Motor Troubleshooting Guide 2 cccccceeeeeeeseeceeeeeeeeeeseneeceneeeeeseeeeesneeeeeeeeeeeneesees 9 7 9 2 TROUBLESHOOTING Engine Troubleshooting Guide If the engine malfunctions check if the way the engine is used is correct If engine malfunctions even if engine is used correctly systematically carry out troubleshooting starting with simple points This chart describes typical troubleshooting procedures Do not unnecessarily disassemble carburetor magneto or engine unless it has been found to be the cause of malfunctioning Engine hard to start Remove spark plug and check spark by cranking engine while having the plug touched against engine block AWARNING Keep the plug as far away as possible from the plug hole To avoid an electric shock do not hold the plug itself Make sure to hold the plug cap Is compression sufficient T Check
40. screw driver A e Inspect the inlet and outlet tubes for cracks kinks dents and fractured seams Repair or replace the radiator if necessary e Check for dirt and insects that may be lodged in the ra diator Clean them out by using compressed air or a low pressure washer CAUTION Using high pressure water as from a car wash fa cility could damage the radiator fins and impair the radiator s effectiveness pl E Deel KDO8000BS2 Radiator COOLING SYSTEM 4 13 elt the air passages of the radiator core are blocked more than 30 by unremovable obstructions or irreparably de formed fins replace the radiator with a new one x If a radiator leak is detected by cannot be spotted visually test it as follows 1 Install the radiator cap and plug the overflow tube A and inlet pipe B Attach an air hose D to the outlet connection C 2 Pressurize the inside of the radiator with compressed air to about 50 to 70 kPa 7 to 10 psi 3 Submerge the radiator in water and look for bubbles E which indicate the location of the leak 4 Repair any leaks or replace it with a new one e Check the radiator filler neck for signs of damage e Check the condition of the top A and bottom B sealing seats in the filler neck They must be smooth and clean for the radiator cap to function properly Radiator Cap Inspection The radiator cap has two functions 1
41. so that the temperature sensing projection and threaded portion are submerged e Suspend an accurate thermometer B in the coolant NOTE OThe switch and thermometer must not touch the con tainer sides or bottom e Place the container over a source of heat and gradu ally raise the temperature of the coolant while stirring the coolant gently KD11000BS2 ENGINE TOP END 5 1 Engine Top End Table of Contents EXploded KETTEN 5 2 SPCCIIGATIONS EE 5 6 Special te 5 8 Cylinder Head E 5 9 Compression Measurement 5 9 Cylinder Head Assembly Removal coooooconnconcccccnoconnconacccnncnnnnnnnnnnnnnnerr rica 5 10 Cylinder Head Assembly Installation oonnoniinnnnnnnnnnooonsnsnccccccnnncin nr 5 11 P sh Rod Installation EE 5 12 SEN Bee de OLI id ie 5 12 Valve Mechanism Removal Installation ooooooncooncconnnoncnoninonnconccoccccinnnr 5 12 Cylinder Head Clean iG DEE 5 14 Cylinder Head InspectiOM EE 5 14 VVS iaa 5 16 Valve Clearance Inspection oocoonccnncnnnnnninnicocccnnccnnccnncrnnr cnn 5 16 Valve Clearance AdjUStMGNt icono Neie 5 16 ValVe Seat INSPSCHOM visir aaa RAS 5 16 Valve Seat Repair errereen re eeki ida a A SEENEN das 5 16 Valve Head ThIEKNESS ir A ai ene aries 5 16 Valve Stem Runout ccc cceec cece cece TEETE E 5 16 Valve Stent Dia Mets ia A A dd id 5 16 Valve Guide Inside Diameter 5 17 Valve Spring Inspection iii A e Aa 5 17 A PISTON EE 5 18 PISTOM
42. spring if necessary e Measure the free length A of the spring x If the measurement is less than the service limit replace the spring Valve Spring Free Length Service Limit Inlet Exhaust 32 9 mm 1 30 in 6F06060351 5 18 ENGINE TOP END Cylinder Piston Piston Removal e Split the crankcase see Camshaft Crankshaft chapter e Remove the camshaft see Camshaft Crankshaft chap ter e Turn the crankshaft to expose the connecting rod cap bolts A e Remove the bolts and take off the connecting rod caps B NOTE ONote the position of the connecting rod caps for rein stalling the caps e Push the connecting rod end into the cylinder and pull the piston and connecting rod out of the cylinder CAUTION Note a location of the circle mark on the piston head in relation to K mark on the connecting rod No 1 cyl piston is opposite of No 2 cyl piston Keep parts together as a set A No 1 Cyl Piston B No 2 Cyl Piston C Circle marks D K Mark E Opposite K Mark e Remove one of the piston pin snap rings A with needle nose plier B e Remove the piston by pushing the piston pin A out the side from which the snap ring was removed KEO6052BS1 o ENGINE TOP END 5 19 Cylinder Piston e Remove the top and second rings with piston ring pliers Special Tool Piston Ring Pliers 57001 115 x If the special too is not availab
43. turn at a time while pressing down very lightly Check the seat width after each turn CAUTION The 32 cutter removes material very quickly Check the seat width frequently to prevent over grinding NOTE OKeep the seat width as close as possible to the STD width e Make a light pass with the 45 cutter to remove any pos sible burrs at the edge of the seat e After resurfacing the seat inspect for even valve seating OApply a machinist s dye to the valve face insert the valve and snap it closed against the seat several times The valve surface should show good contact all the way around Be sure the valve seat is centered on the valve face The position of the valve in the seat is evident after lapping the valve If the seat does not make proper contact lap the valve into seat with a lapper e Coat the face of valve sparingly with a fine lapping com pound e Use the lapper A to grip top of the valve B Rotate the valve in a circular motion to lap the valve to the seat e Lift the valve slightly from the seat every 8 to 10 strokes continue lapping operation until a uniform ring appears around entire surface of the valve face KEO5006BS1 o 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures e When lapping is completed wash all parts in solvent to remove lapping compound Dry the parts thoroughly e Note the position of the lapping mark on the valve face The lappin
44. 14 Element Cleaning and Inspection 3 24 Low Idle Speed Adjustment 3 14 Cleaner Body Removal 3 24 High Idle Speed Adjustment 3 14 Cleaner Body Installation 3 25 High Altitude Operation 3 14 Housing Inspection ooo co cc 3 25 Main Jet Replacement 3 15 Air Cleaner Heavy Duty Type 3 26 Fuel System Cleanliness Element Hemoval 3 26 Inspechon eneee 3 15 Element Installaton 3 26 Carburetor Removal 3 15 Element Cleaning and Inspection 3 26 Carburetor Installation 3 15 Cleaner Body Removal 3 26 Carburetor Disassembly Assem Cleaner Body Installation 3 27 DIY aiii Behan eebe Ren 3 17 Housing Inspection 3 27 3 2 FUEL SYSTEM Exploded View Standard Air Cleaner Model FUEL SYSTEM 3 3 Exploded View Fastener Remarks 1 Carburetor and Inlet Pipe Mounting Bolts and Nuts 104 in lb 2 Inlet Manifold Mounting Bolts E 53 in lb 3 Pilot Jets S 15 mb 4 Main Jets 6 in lb 6 Fuel Shut Off Solenoid Valve 7 0 0 71 61 in lb 7 Drain Screw 1 3 0 13 11 in lb 8 Air Cleaner Wing Nuts 2 0 2 17 in lb L Apply a non permanent locking agent R Replacement Parts S Follow the specific tightening sequence 3 4 FUEL SYSTEM Exploded View Heavy Duty Air Cleaner Model Kc020278W5 Exploded View FUEL SYST
45. 15 mm 0 006 in 45 0 8 1 4 mm 0 031 0 055 in 1 1 1 6 mm 0 43 0 063 in 7 000 7 015 mm 0 2756 0 2762 in 75 18 75 2 mm 2 598 2 9606 in 5 8 ENGINE TOP END Special Tools Piston Ring Pliers 57001 115 ST5701158T Compression Gauge 20 kgf cm 57001 221 Piston Ring Compressor Grip 57001 1095 T5702218T ST5710958T Piston Ring Compressor Belt 67 79 57001 1097 ST5710978T Compression Gauge Adapter M14 x 1 25 57001 1159 ST5711598T ENGINE TOP END 5 9 Cylinder Head Compression Measurement e Before measuring compression do the following OBe sure the battery is fully charged OThoroughly warm up the engine so that engine oil be tween the piston and cylinder wall will help seal compres sion as it does during normal running OStop the engine e Disconnect the spark plug caps of each cylinder and re move the spark plugs e Attach the compression gauge assembly firmly into one plug hole Special Tools Compression Gauge 20 kgf cm 57001 221 A Compression Gauge Adapter M14 x 1 25 57001 1159 B e Ground the spark plugs to the engine A WARNING To avoid fire do not ground the spark plugs in closed positions to the plug holes Keep the plugs as far away as possible from the plug holes e Using the starter motor turn the engine over with the throt tle fully open unti
46. 5 e Inspect the cylinder head for accumulation of rust scale and lime in the water jacket A x If this accumulation is observed flush the cooling system see Cooling System chapter e Measure the diameter A of the rocker arm collar with a micrometer at several points of bearing the rocker arm x lf the outside diameter is less than the service limit re place the rocker arm collar Rocker Arm Collar Outside Diameter Service Limit Inlet Exhaust 10 914 mm 0 4297 in e Clean and inspect the rocker arm where it touches the push rod and valve stem x If the contact points A are worn or damaged replace the rocker arm e Measure the inside diameter of the rocker arm bearing B at several points using a dial bore gauge or inside micrometer x lf the inside diameter is more than the service limit re place the rocker arm Rocker Arm Bearing Inside Diameter Service Limit Inlet Exhaust 11 132 mm 0 4382 in 5 16 ENGINE TOP END Valves Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Clearance Adjustment e Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Seat Inspection e Refer to the Valve Seat Inspection in the Periodic Mainte nance chapter Valve Seat Repair e Refer to the Valve Seat Repair in the Periodic Mainte nance chapter Valve Head Thickness e Remove the valve see Valve Mechanism
47. Allow atmospheric pressure to enter the cooling system 2 Prevents coolant escape at normal operating pressure A pressure valve E in the cap permits the escape of coolant or steam when the pressure in the system rises above the relief pressure A vacuum valve D in the cap opens when needed to prevent a vacuum in the cooling system e Check the condition of the valve spring A and the top B and bottom C valve seats of the radiator cap x If any one of them shows visible damage replace the cap e Wet the radiator cap B seating surfaces with water or coolant to prevent pressure leaks e Install the cap on a cooling system pressure tester A e Watching the pressure gauge pump the pressure tester to build up the pressure The cap must retain the pres sure at least 6 seconds Also the cap must open at the pressure shown in the table Radiator Cap Relief Pressure Pressure Valve 73 3 102 7 kPa 0 75 1 05 kgf cm 10 6 14 9 psi Vacuum Valve 4 90 kPa 0 050 kgf cm 0 71 psi x If the cap cannot hold the specified pressure or if it holds too much pressure replace it with a new one 4 14 COOLING SYSTEM Radiator Radiator Hose Inspection ein accordance with the Periodic Maintenance Chart visually inspect the hoses A for signs of deterioration Squeeze the hose A hose should not be hard and brittle nor should it be soft or swollen e Replace any damaged hose NOTE OHoses ca
48. EM 3 5 Fastener Carburetor and Inlet Pipe Mounting Bolts and Nuts 104 in lb Inlet Manifold Mounting Bolts 53 in lb Pilot Jets 15 mb Main Jets 2 0 6 in lb inb 1 2 3 4 5 Float Chamber Mounting Screws 6 7 8 Fuel Shut Off Solenoid Valve 7 0 0 71 61 in lb Drain Screw 1 3 0 13 11 in Ib Air Cleaner Tube Clamps 2 0 2 17 in lb R Replacement Parts S Follow the specific tightening sequence 3 6 FUEL SYSTEM Exploded View B KC02028BW5 Exploded View FUEL SYSTEM 3 7 Torque D Fastener 1 Governor Arm Clamp Nut kgf m 0 8 69 in lb O Apply engine oil 3 8 FUEL SYSTEM Specifications Item Standard FD680V FD731V Caburetors Specifications Make type MIKUNI BW26 Throttle Bore Diameter 26 mm 1 02 in Venturi Diameter 21 mm 0 83 in Main Jet MJ R 130 L 128 8 R 120 L 115 Pilot Jet PJ R 50 L 46 3 Main Air Jet MAJ p1 7 Pilot Air Jet PAJ p1 2 Pilot Air Screw Turns Out PS Idle Mixture Screw Turns Out Float Level R 2 3 4 L 3 5 8 R 2 7 8 L 3 11 16 Float parallel to carburetor body Idle Speed 1 Low Idle Speed High Idle Speed Air Cleaner Standard Model Type Pre Cleaner Two Stage cleaner Heavy Duty Model 1 550 r min rpm 3 600 r min rpm Dual stage filtration system Foam element Paper element
49. Installation e Fit the sleeve into the governor assembly and install them as a set NOTE OThe sleeve and the governor assembly cannot be in stalled separately Push the set onto the shaft until in ner flange snaps into the groove securely Sleeve A Governor Assembly B Inner Flange C Thrust Washer D Groove E Shaft F e Spin the governor assembly by hand and check that the flyweights operate freely and the center sleeve moves outward Governor Assembly Inspection OVisually check the assembly for wear and damage x If any parts is worm or damaged replace the assembly Governor Shaft Removal e Remove Camshaft see Camshaft Tappet Removal in the Camshaft Crankshaft chapter e Unscrew the governor arm clamp nut and remove the governor arm e Remove the circlip B on the governor shaft C and re move the governor shaft and washer A NOTE Olt is not necessary to remove the governor shaft unless it is being replaced e Replace the oil seal only if the lip shows signs of leakage or it has been damaged e The oil seal A must be assembled with seal lip towards inside of the engine e Press in the oil seal as shown 0 5 mm 0 0 04 in B Crankcase Surface C Governor Shaft D KC04016B51 KC04018B51 KC04017B51 3 12 FUEL SYSTEM Governor Link Mechanism Governor Shaft Installation e Apply engine oil to the governor shaft e Insert the
50. ON SYSTEM Engine Oil Flow Chart 4 4 ee N Zz ditt SSS Ss Ge Ce pm LI EAA T RI ES a KF040058W 5 LUBRICATION SYSTEM 6 5 Special Tools and Sealant Oil Pressure Gauge 10 kgf cm Kawasaki Bond Silicone Sealant 57001 164 56019 120 ST5701648T ST560120ST Oil Pressure Gauge Adapter PT 1 8 57001 1033 ST5710338T 6 6 LUBRICATION SYSTEM Specifications Item Standard Engine Oil Grade API service classification SF SG SH or SJ class Viscosity SAE40 SAE30 SAE10W 30 SAE10W 40 or SAE5W 20 Capacity 2 0 L 2 1 US qt When filter is not removed 2 3 L 2 4 US qt When filter is removed Level Between ADD and FULL marks Oil Pressure 294 686 Kpa 42 6 99 5 psi Engine oil temperature 50 60 C Oil Pressure Switch Detect Pressure 98 kPa 14 2 psi Screw PT 1 8 pipe thread Oil Filter By pass Valve Opening Pressure 69 127 kPa 10 18 4 psi Item Service Limit Oil Pump Inner and Outer Rotor Clearance 0 21 mm 0 0083 in Outer Rotor Outside Diameter 40 470 mm 1 5933 in Outer Rotor Thickness 9 94 mm 0 391 in Pump Housing Inside Diameter 40 801 mm 1 6063 in Pump Housing Depth 10 230 mm 0 4028 in Pump Shaft Outside Diameter 10 923 mm 0 4300 in Relief Valve Spring Free Length 19 50 mm 0 7677 in Pump Shaft Bearing Inside D
51. Q position and check the resistance between each segment and all the others x lf the resistance it too high or even infinite the armature winding has an open circuit Replace the starter motor Armature Winding Resistance Close 0Q KHO9013BS1 6P110607581 KHOS014BS1 Electric Starter System ELECTRICAL SYSTEM 8 21 e Set the multimeter selector switch to the R x 1 KQ position and measure the resistance between the commutator and the armature shaft x If the resistance is less than infinite the armature is shorted Commutator to Shaft Resistance e Test the armature winding for shorts OPlace the armature on a growler A OHold a thin metal strip e g hack saw blade on top of the armature OTurn on the growler and rotate the armature one complete turn lf the metal strip vibrates the windings are internally shorted to each other and the starter motor must be replaced Yoke Assembly Inspection e Set the multimeter selector switch to the R x 1 KQ position and measure the resistance between the positive brushes A and stator motor yoke x If the resistance is less than infinite the positive brush is shorted to ground Replace the yoke assembly Positive Brush to Ground Resistance e Set the multimeter selector switch to the R x 1 Q posi tion and measure the resistance between the negative brushes A and starter motor yoke x lf the meter dose not
52. Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Place a suitable pan under the drain screw A on the carburetor B e Turn out the drain screw a few turns to drain the carburetor and check to see if water or dirt has accumulated in the carburetor e Tighten the drain screw lf any water or dirt come out clean the carburetor see Carburetor Cleaning and fuel tank and check the fuel filter Element Cleaning and Inspection Standard Type NOTE Oln dusty areas the elements should be cleaned more frequently than the recommended intervals KCO4038BS2 C 2 10 PERIODIC MAINTENANCE Periodic Maintenance Procedures A WARNING Because of the danger of highly flammable liquids Y do not use gasoline or a low flash point solvent to ee 78 clean the element e Remove the foam element A and the paper element B e Clean the foam element in detergent and water and dry it thoroughly e Clean the paper element B by tapping it gently on a flat surface to remove dust If the element is very dirty re place it with a new one or wash the element in a detergent and water e Rince the element until a water is clear Let the element air dry thoroughly before install it CAUTION Do not use compressed air to clean the paper ele ment Do not oil the paper an
53. aging the heads 6 Edges Watch for sharp edges especially during major engine disassembly and assembly Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over 4 7 High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent com monly available in North America is Standard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent 8 Gasket O Ring Do not reuse a gasket or O ring once it has been in service The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks 9 Liquid Gasket Non Permanent Locking Agent Follow manufacturer s directions for cleaning and preparing surfaces where these compounds will be used Apply sparingly Excessive amounts may block engine oil passages and cause serious damage An example of a non permanent locking agent commonly available in North America is Loctite Lock n Seal Blue 10 Press A part installed using a press or driver such as a journal should first be coated with oil on its outer or inner circumference so that it will go into place smoothly 11 Ball Bearing When installing a ball bearing the bearing race which is affected by friction should be pushed by a suitable driver This prevents severe stress on the balls and races and prevents races and balls from being dent
54. and install the cap x lf the pressure drops and no external source is found check for internal leaks Droplets in the engine oil indicate internal leakage Check the cylinder head gaskets Flushing Over a period of time the cooling system accumulates rust scale and lime in the water jacket and radiator When this accumulation is suspected or observed flush the cool ing system If this accumulations is not removed it will clog up the water passage and considerably reduce the ef ficiency of the cooling system A WARNING Prior to disassembly of cooling system parts radi ator pump sensor etc wait until the coolant cools down and then drain the coolant CAUTION After assembling and filling the system with a coolant purge any air from the system e Drain the cooling system e Fill the cooling system with fresh water mixed with a flush ing compound CAUTION Avoid the use of a flushing compound which is harmful to the aluminum engine and radiator Carefully follow the instructions supplied by the manufacturer of the cleaning product e Warm up the engine and run it at normal operating tem perature for about ten minutes e Stop the engine and drain the cooling system e Fill the system with fresh water e Warm up the engine and drain the system e Repeat the previous two steps once more e Fill the system with a permanent type coolant and bleed the air from the system
55. battery Faulty leads or connection Solenoid to motor Is battery normal and well NO Weak battery charged Y Faulty solenoid switch Main terminal in solenoid Faulty starter motor Charge or replace H Repair or replace Replace H Repair or replace H Charge or replace Faulty leads or connection Solenoid to motor Faulty solenoid switch STARTER ROTATES BUT CAN NOT CRANK ENGINE Main terminal in solenoid Faulty starter motor Faulty engine Repair or replace Replace Repair or replace Repair or replace Does pinion mesh with ring gear STARTER DOES NOT STOP IN ENGINE SWITCH OFF NO gt Worn pinion or ring gear Replace lncorrect starter alignment Correct gt Faulty pinion clutch Replace Faulty engine Repair or replace Can stop starter by engine switch OFF NO Y OFaulty engine switch Faulty solenoid switch Repair or replace Replace Faulty pinion or ring gear Y O incorrect starter alignment Faulty pinion return mechanism H Repair or replace E Correct Repair or replace WE Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 2065 01 Printed in Japan
56. 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 Electrical Wires All the electrical wires are either single color or two color and with only a few exceptions must be connected to wires of the same color On any of the two color wires there is a greater amount of one color and a lesser amount of a second color so a two color wire is identified by first the primary color and then the secondary color For example a yellow wire with thin red stripes is referred to as a yellow red wire it would be a red yellow wire if the colors were reversed to make red the main color Wire cross section Color Indicated on the Wire Color Indicated on the Wiring Diagram Yellow Red mmm hu 6B020601w1 17 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 fun
57. buretor see Fuel System chapter Control Panel see Fuel System chapter Muffler and Exhaust Pipe see Engine Top End chapter Inlet Manifold see Fuel System chapter Spark Plugs see Electrical System chapter Thermo Switch Terminal e Unscrew the rocker cover mounting bolts C and remove the covers and gaskets A Rocker Cover No 1 Cylinder B Rocker Cover No 2 Cylinder C Mounting Bolts 4 Bolts e When removing the cylinder head set the flywheel at top dead center T D C of power stroke each cylinder OWhen setting the flywheel at T D C of 1 cylinder align the center of the flywheel magnet A with No 1 ignition coil B If it is not at T D C turn the flywheel clockwise one turn 360 OWhen setting the flywheel at T D C of 2 cylinder turn the flywheel magnet clockwise from position at T D C of 1 cylinder to at No 2 ignition coil C If itis not at T D C turn the flywheel clockwise with one turn 360 KE04021BS1 o Cylinder Head ENGINE TOP END 5 11 e Loosen the cylinder head bolts 1 4 turn in the sequence shown CAUTION If the above procedure is not followed the cylinder head may be warped during removal e Repeat the sequence until all bolts are removed and lift off the cylinder head assembly NOTE OMark the push rods so they can be installed in their orig inal position during assembly Cylinder Head Assembly Installation e When installing the cylinder head
58. changed periodically to ensure long engine life CAUTION Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instructions of the manufac tures see Coolant Filling Section 4 8 COOLING SYSTEM Coolant A WARNING To avoid burns do not remove the radiator cap or try to change the coolant when the engine is still hot Wait until it cools down Since coolant is harmful to the human body do not use for drinking e Remove the radiator cap A as follows OFirst turn the cap counterclockwise to the first stop and wait there for a few seconds OPush down the cap then turn the cap counterclockwise to the next stop OL off the cap e Place a suitable container under the drain plug B black head Turn the drain plug counterclockwise to drain the coolant in the radiator and water jacket e Inspect the old coolant for color and smell see Coolant Deterioration in this chaoter Coolant Filling e Refer to the Coolant Filling in the Periodic Maintenance chapter Air Bleeding Before putting the engine into operation any air trapped in the cooling system must be removed as follows e Remove the radiator cap e Fill the radiator up to the radiator filler neck with coolant e Check the cooling system for leaks e Install the radiator cap e Start the engine warm it up thoroughly and then stop it e Check the coolant level i
59. ction once removed 18 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure 19 Specifications Specification 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 deteri orated performance replace the damaged parts 1 4 GENERAL INFORMATION Model Identification FD680V FD731V 038010 P Cylinder Number Designation No 1 Cyl is on the electric starter side No 2 Cyl is on the oil filter side GENERAL INFORMATION 1 5 General Specifications Items Type of engine Liquid cooled Vertical shaft OHV 4 stroke 90 V twin Gasoline engine Bore x Stroke 75 2 mm x 76 mm 2 96 in x 2 99 in Piston displacement 675 mL 41 2 cu in Direction of rotation Counterclockwise facing the PTO shaft Low idle speed 1 550 r min rpm High idle speed 3 600 r min rpm Ignition system Solid state ignition RFI Per Canada and U S A requirements Starting system Shift type electric starter Charging system 12 V 20 A with regulator Float type fixed main jet Fuel pump Diaphragm type pulse pump Air cleaner Dual stage element dr
60. d foam element Do not use pressurized air to clean or dry paper ele ment Heavy Duty Type This air cleaner elements are not recommended to be cleaned and each air cleaner element should be replaced with the new one at the maintenance time as shown in the maintenance chart NOTE OOperating in dusty condition may require more frequent maintenance than above e Replace the primary element A every 250 hrs e Replace the secondary element B with the new one if dirty when primary element is checked e Replace the secondary element every 500 hrs CAUTION Do not wash air cleaner elements Do not oil air cleaner elements Do not use pressurized air to clean air cleaner elements Housing Case and Body Inspection e Clean the housing with detergent and water and dry thor oughly e Check the housing for deformation or other damage The housing must seal well and permit only filtered air to reach the carburetor x If the housing is damaged it must be replaced e Check that no foreign material is obstructing the air pas sage PERIODIC MAINTENANCE 2 11 Periodic Maintenance Procedures Cooling System Coolant Filling e Install the drain plug Always replace the gaskets with a new ones e Tighten the drain plug to the specification Torque Coolant Drain Plug 15 N m 1 5 kgf m 11 ft lb e Fill the radiator up to bottom of the radiator filler neck A with coolant and install the cap
61. ds across the large terminals A as shown OTurn the engine switch to the START II position and read the tester x lf the solenoid does not click or if the tester reads more than 0 Q the solenoid is faulty Replace it x If the solenoid makes a single clicking sound the tester reads 0 Q and the rest of the starter circuit is good x lf solenoid clicks once but the tester does not read 0 Q the solenoid is faulty Replace it x lf the solenoid does not click at all proceed with the fol lowing e Disconnect the switch lead A shown 8 16 ELECTRICAL SYSTEM Electric Starter System e Set the hand tester to the R x 1 Q position and connect the leads as shown Switch Terminal A To Ground B x lf the tester does not read close to 0 Q the solenoid is faulty Replace it x If the tester reads close to 0 Q the solenoid may be good e Check the voltage to the solenoid from the engine switch e Set the hand tester selector switch to the 25 V DC position and connect it as shown Switch Lead Connector A To Ground B e Turn the engine switch to the START II position and read the tester x lf the tester reads battery voltage the circuit is good x lf the tester reads much less than battery voltage or no voltage at all either the wiring or the engine switch is bad Check the engine switch or the wiring for damaged or broken wires and replace as required Starter Motor Test NOTE OAlways inspect the Sta
62. e Engine Troubleshooting Guide TROUBLESHOOTING 9 3 Engine loss power Crankcase low on oil Too much oil in crankcase Excessive engine load O Carb not properly adjusted Carbon deposit in combustion chamber Lack of coolant Clogging of cooling system Damaged cooling fan O Malfunction water pump or thermostat Aeration in cooling system Lodged dirt and insects in radiator Damaged radiator Deteriorated coolant Adjust level or add Adjust level Decrease load Adjust Clean Fillcoolant Clean H Replace H Replace Purge air HE Clean H Replace Change Is engine overheated YES gt NO Y ls the ignition spark NO gt normal YES i Is lubrication condition normal NO gt YES Is unusual smoke emitted out of muffler Is compression sufficient YES gt a NO NO gt Engine runs erratically 4 H _ gt Problem in the fuel Wrong spark plug O Faulty ignition coil Incorrect air gap Replace Replace Adjust gap e Too much or too little oil in crankcase O Excessively contaminated lub ricating oil O Defective oil filter O Faulty relief valve Faulty oil pump O Clogging oil system Plugged air cleaner Carbon deposit in exhaust hole and muffler O Carb not prope
63. e Ea eA EEEE E EERE E E E 7 6 Crankcase Cover Installation ooooooonnnncccnncnnncnnnnnnnnnnnnnnnnnnnnonnnonononnnnnnnnnnnnnnnnnnninnninss 7 6 INSPECUON EE 7 8 EI un EE 7 9 Breather Valve Removal ccccccecccecccececeeceeeeeeeeeeeeeeeeeeeeeeeeeeeceeeeeesecaeeeseseeseseseeeeeenenaags 7 9 Breather Valve Installation moriren ee eaaa ea aaaea ata iE aED 7 9 Breather Valve Inspection oocccccccccnncnnccnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninnnnnnnninnnss 7 9 Camshaft Tapper oi 7 10 Camshaft Tappet HRemova EEEE EEEEEEEEEEEEtEEnt 7 10 Camshaft Tappet Installaton 7 10 Camishatt InSpeciON onc dd cacdonciseassessacoandcstcescttoneeteets 7 10 Camshaft Bearing Journal Wes cent EEN a 7 10 Crankshaft Connecting Rod 7 12 Connecting Rod Removal coi A AA a a A ee 7 12 Connecting Rod Install ce sa cet ce cck vac docc eds out Ai Wise ot sida arrancada te ahh aerate 7 12 Crankshaft REMOVa ls eenzegt Socks cece e de EES lead 7 12 Crankshaft Installation oooooconnnnnncccnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnos 7 12 Cleaning Inspector msi didas 7 12 Connecting Rod Bend MiS tissue E 7 13 Connecting Rod Big End Crankpin Width Wear ccccccnnncccoccccncccccncccnnancnononononcnnnana conc 7 13 Connecting Rod Big End Bearing Crankpin Wear oooncnccccnnccccccccnnnnnonanncnncnnnnnnnnannnnn cnn 7 14 Cranks ha i RUNOUC seis T a a a a a a E e arae aT a r a aaao 7 14
64. e tapered portion A of the pilot screw B for wear or damage x If the pilot screw is worn or damaged on the taper portion replace it e Check the spring for weakened condition replace it if necessary Fuel Shut Off Solenoid Valve Test e Unscrew the fuel shut off valve and remove the valve e Connect a 12 VDC source to the solenoid as shown x lf the actuate solenoid plunger needle valve does not pop in when the test voltage is applied replace it NOTE Olf may be necessary to push the plunger slightly for the plunger to withdraw e Install the gasket and the valve Torque Fuel Shut Off Solenoid Valve 7 0 N m 0 71 kgf m 61 in Ib Inlet Manifold FUEL SYSTEM 3 21 Inlet Manifold Removal e Remove Air Cleaner and Related Parts see Element Removal and Cleaner Body Removal in this chapter Carburetor see Carburetor Removal in this chapter Control Panel Assembly e Drain the coolant in the engine see Coolant Draining in the Cooling System chapter e Unscrew the manifold mounting bolts in numerical se quence 1 4 turn at a time until all bolts are loose x If the mounting bolts removal sequence is not followed manifold mating surfaces may be warped e Remove the manifold A and gaskets Inlet Manifold Installation e Before assembling the manifold A install the cylinder heads on each cylinder and tighten the head bolts see Cylinder Head Assembly Installation in the Engine Top End chapter e
65. e voltage inspect showed the alternator to be defective the rotor magnets have probably weakened and the rotor must be replaced To Stator A Ohm Meter B Stator Coil Connector C 730P700781 C 8 10 ELECTRICAL SYSTEM Charging System e Check for continuity between each stator pin and ground There should be no continuity infinite ohm x lf the stator coil fails any of these tests replace the coil with a new one To Stator A Stator Coil Connector B Unregulated Stator Output e Disconnect the stator coil connector e Connect AC voltmeter to the stator pins e Start the engine Run the engine at the 3 000 rpm speed e Voltage reading should be minimum 26 V AC 3 000 rpm x lf the AC voltage reading is less than the specification replace the stator Unregulated Stator Output 26 V AC 3 000 rpm Stator Coil Connector A To Stator B AC Voltmeter C Regulator Removal e Remove Starter Coil Lead Connector A Regulator Bolts B Regulator C Harness Lead D Regulator Installation EAS e Install the regulator A and tighten the bolts B OHarness lead C is tighten with the bolt e Apply grease to the female and male connectors D and connect it Torque Regulator Bolts 6 N m 0 6 kgf m 53 in Ib Grease Three Bond TB2585G or Grease No Rykon pre mum grease EP 2 general purpose Green KHO7036BS1 o Charging System ELECTRICAL SYSTEM 8 11
66. ecial Tools and Gealant r aa e a a aE AE A AN 6 5 eigene EE 6 6 Engine Oil and Oil Filter ooo aaa 6 7 Oil Level Inspection asilo adi EIERE 6 7 KO EE Zeene O Monae Ge Genie 6 7 OM Filler REMOVAL she codi asada 6 7 Oil Filter Installation ooccoccconncnnncnnnnnnnnnnnnnnnnnnnnnnnnnnonononnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnss 6 7 Pressurized Lubrication System rtorras tro did di ia 6 8 Oil Pressure Measurement oococccnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninnniis 6 8 Oil Pressure Switch Inspection oocccccccccnnnnnnnnnnnnnnnnnnnnnnnnonnnnnnnonononnnnnnnnnnnnnnnnnnnnninininss 6 9 Oil Pump and Relief Valve nana r rr rre 6 10 Oil Pump Relief Valve Hemoval 6 10 Oil Pump Relief Valve Installation nnnnnnnnnenesnnenenerresrrrsrrrsrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrererrrrnn 6 10 Oil Pump Relief Valve Inspechon 6 10 OMSrS NEE 6 13 Oil Screen Filter Removal 6 13 Oil Screen Filter Cleaning and InSpection ccccceeesseceeeceeeeeeeteeeesenecseeeeneeeeeseneenenes 6 13 6 2 LUBRICATION SYSTEM Exploded View KF02008BW5 C LUBRICATION SYSTEM 6 3 Exploded View Remarks Fastener 6 9 0 70 61 in lb 9 8 1 0 87 in lb SS 1 Oil Drain Plugs 2 Oil Pressure Switch L Apply a non permanent locking agent O Apply engine oil R Replacement Parts SS Apply Silicone Sealant Kawasaki Bond 56019 120 6 4 LUBRICATI
67. ed KG06025BS1 o Connecting Rod Bend Service Limit 0 2 100 mm 0 008 3 94 in e Measure connection rod twist OWith the big end arbor still on the V blocks hold the con nection rod horizontally and measure the amount that the small end arbor varies from being parallel with the surface plate over a 100 mm 3 94 in length of the arbor to de termine the amount of connecting rod twist x If connecting rod twist exceeds the service limit the con necting rod must be replaced Connecting Rod Twist KGO6026BS1 Service Limit 0 2 100 mm 0 008 3 94 in Connecting Rod Big End Crankpin Width Wear e Measure the connecting rod big end width A with a mi crometer or dial caliper x If the measurement is less than the service limit replace the connecting rod Connecting Rod Big End Width Service Limit 20 2 mm 0 795 in e Measure the crankpin width B with a dial caliper x If the crankpin width is more than the service limit replace the crankshaft Crankpin Width Service Limit 45 0 mm 1 772 in 7 14 CAMSHAFT CRANKSHAFT Crankshaft Connecting Rod Connecting Rod Big End Bearing Crankpin Wear e Apply a light film of oil on the thread of the cap bolts e Install the cap bolts and tighten the bolts to the speci fied torque see Piston Installation in the Engine Top End chapter e Measure the inside diameter A of both big ends with a inside micrometer x lf the inside d
68. ed Press a ball bearing until it stops at the stop in the hole or on the shaft 12 Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally dam ages seals GENERAL INFORMATION 1 3 Before Servicing 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 13 Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips Before a shaft passes through a seal apply a little oil preferably high temperature grease on the lips to reduce rubber to metal friction 14 Circlip Retaining Ring and Cotter Pin When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more Install the circlip with its chamfered side facing load side as well Replace any circlips retaining rings and cotter pins that were removed with new ones as re moval weakens and deforms them If old ones are reused they could become detached while running leading to a problem 15 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film During assembly oil or grease whichever is more suitable should
69. edo de e ae cado 8 21 Pinion Clutch Inspection occccccnncnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnononnnnnnnnnnnnnnnnnnninnnnnnninnnnss 8 21 8 2 ELECTRICAL SYSTEM Exploded View KH02014BW5 C ELECTRICAL SYSTEM 8 3 Exploded View No Fastener Tordus Remarks N m kgf m ft Ib 1 Flywheel Bolt 56 5 7 41 2 Stator Coil Screws 3 4 0 35 A Ignition Coil Mounting Bolts 3 4 0 35 30 in lb S 4 Spark Plugs 25 2 5 5 Thermo Switch 28 2 8 21 SS 6 Oil Pressure Switch 10 1 0 87 in lb SS 7 Starter Motor Mounting Bolts 15 1 5 11 8 Regulator Bolts 6 0 6 53 in lb G1 Apply grease G2 Apply grease Three Bond TB2585G or Grease No Rykon premum grease EP 2 general purpose Green O Apply engine oil R Replacement Parts S Follow the specific tightening sequence SS Apply silicone sealant 8 4 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Charging System Regulated Output Voltage Alternator Stator Coil Resistance Unregulated Stator Output Regulator Resistance Battery voltage to 15 V DC 0 20 See charging system 26 V AC 3 000 rpm Ignition System Ignition Coil Primary Winding Resistance Secondary Winding Resistance Spark Plug Plug Gap 16 240 17 25k0 NGK BPR2ES 0 75 mm 0 030 in Electric Starter System Starter Motor Carbon Brush Length Commutator Groove Depth Commutator Diameter Commutator Runout
70. ee Carburetor Removal in this chapter e Unscrew the float chamber screws and take off the float chamber B e Using a proper blade screw driver carefully replace the main jet C with a new one for altitude expected e Tighten the main jet to the specification see Carburetor Disassembly Assembly in this chapter Torque Main Jets 0 7 N m 0 07 kgf m 6 in Ib e Install the gasket and float chamber Torque Float Chamber Mounting Screws 2 0 N m 0 20 kgf m 17 in lb Fuel System Cleanliness Inspection e Refer to the Fuel System Cleanliness Inspection in the Periodic Maintenance chapter Carburetor Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove Air Cleaner and Related Parts see Element Removal and Cleaner Body Removal in this chapter e Turn the fuel shut off valve to the OFF position e Drain the carburetor e Disconnect the fuel tube A at the fuel inlet joint of the carburetor e Unhook the throttle rod B and spring C and choke link rod D at the ends of their arms while pull off the carbu retor Carburetor Installation e Refer to the illustration shown for installation Install the carburetor with the following procedures OClean the mating surfaces of the ca
71. em chapter Cooling Fan see Cooling Fan Removal in the Cooling System chapter Starter Motor see Starter Motor Removal in this chapter Ignition Coils see Ignition Coil Removal in this chapter Cooling Fan Extension e Hold the flywheel A with a suitable tools remove the flywheel bolt B e Using a suitable flywheel puller A remove the flywheel B NOTE Olf a flywheel puller is not available screw the flywheel bolt and tap sharply and squarely on the bolt end to break the flywheel loose Flywheel will loose e Note the stator coil output leads A position for reinstalling the stator coil e Remove Woodruff Key B Stator Coil Screws C Stator Coil D Flywheel Stator Coil Installation e Apply grease to the female and male starter coil connec tors and connect it Grease Three Bond TB2585G or Grease No Rykon pre mum grease EP 2 general purpose Green Install the stator coil and tighten the screws Torque Stator Coil Screws 3 4 N m 0 35 kgf m 30 in Ib e Using a cleaning fluid clean off any oil or dirt on the fol lowing portions and dry them with a clean cloth Crankshaft Tapered Portion A Flywheel Tapered Portion B e Fit the woodruff key C securely in the slot in the crank shaft before installing the flywheel Charging System ELECTRICAL SYSTEM 8 9 e Install the flywheel onto the crankshaft taper so that the woodruff key fits in the key way in the hub of the flywheel e P
72. emove the insulator A e Using a needle nose pliers remove the brush springs A from the brush holder B e Separate the brushes C from the holder and remove the holder from the yoke D Starter Motor Assembly Notes e Apply a small amount of grease to the armature shaft A as shown e Do not reuse the snap ring B Replace it with a new one e Inspect the boots A for visible damage x If it is damaged replace it e Fit the notch A in the lead grommet onto the projec tion B on the end cover C Electric Starter System ELECTRICAL SYSTEM 8 19 e Grease the pinion gear fork fingers e Set the pinion gear fork so that the fingers fit into the groove in the gear e Fit the notch A in the yoke onto the projection B on the pinion gear fork e Engage the hook on the starter solenoid with the hook A on the pinion gear fork B Starter Motor Brush Inspection e Measure the overall length of each brush A x If the brushes are shorter than the service limit replace them Brush Length Standard 10 mm 0 394 in Service Limit 6 0 mm 0 24 in Brush Spring Inspection e Inspection the brush springs for pitting cracks rusting and burrs Replace the spring if necessary e Inspect the springs for weakened conditions and distor tion Replace the springs if necessary x If the brush springs are able to press the brushes firmly into place they may be considered serviceable If t
73. ents to clean the carburetors CAUTION Do not use compressed air on an assembled car buretor the float may be crushed by the pressure Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carbure tor with a cleaning solution This will prevent dam age or deterioration of the parts The carburetor body has plastic parts that cannot be removed Do not use a strong carburetor cleaning solution which could attack these parts instead use a mild high flash point cleaning solution safe for plastic parts Do not use wire or any other hard instrument to clean carburetor parts especially jets as they may be damaged e Disassemble the carburetor e Immerse all the carburetor metal parts in a carburetor cleaning solution and clean them e Rinse the carburetor parts in water and dry them with compressed air e Do not use rags or paper to dry parts Lint may plug the holes or passages e Blow air through the holes and fuel passages with the compressed air All holes must be open e Assemble the carburetor Carburetor FUEL SYSTEM 3 19 Carburetor Inspection A WARNING Gasoline is extremely flammable and can be explo sive under certain Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Inspect the carburetor body for damage Flange sealing su
74. epair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want ignition coil informa tion use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the Ignition coil section 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 s
75. es even at low engine speed Choke Valve B Fuel flow in the pilot system is metered by the pilot jet Air for better atomization is admitted via the pilot air jet in the mid way of the carburetor The fuel air mixture passes into the bore of the carburetor downstream of the throt tle valve through the bypass holes and pilot outlet While the throttle valve is almost closed it covers the small by pass holes opening into the bore from the pilot system As the throttle valve begins to open it uncovers the bypass holes allowing more fuel air mixture to flow The extra flow is needed because the engine starts to run faster as the throttle is opened The pilot screw controls the amount of fuel air mixture allowed through the pilot outlet but dose not meter the bypass holes A moderate amount of air comes in around the throttle valve at an idle so adjusting the pilot screw changes the fuel air ratio Turning the pilot screw idle mixture screw out counterclockwise enriches the mixture turning it in clockwise leans the mixture 730P028152 730P028252 3 14 FUEL SYSTEM Carburetor Fuel Shut Off Solenoid Valve To avoid after firing when stopping the engine a solenoid actuated fuel shut off solenoid valve A is installed in the carburetor bowl The valve shuts off the fuel supply to the main jet B simultaneously when the switch key turned to the OFF position
76. extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Disconnect the fuel pump outlet nozzle from the tube e Connect a suitable hose A to the outlet nozzle e Run the lower end of the hose into a container e Start the engine check the fuel flow x If fuel flow is none or little replace the fuel pump x Check for clogged or damaged tubes and fuel filter Re place the faulty parts Fuel Filter FUEL SYSTEM 3 23 Fuel Filter Inspection e Visually inspect the fuel filter A x lf the filter is clear with no signs of dirt or other contami nation it is OK and need not be replaced x lf the filter is dark or looks dirty replace with a new one Also check the rest of the fuel system for contamination 3 24 FUEL SYSTEM Air Cleaner Standard Type Element Removal e Remove Air Cleaner Case Nuts A Upper case B e Remove Wing Nuts A Foam Element B Paper Element C Element Installation e Install the element correctly on the air cleaner body e Be sure the paper element is in place in the air cleaner body e Be sure the foam element is in place on the paper ele ment body e Tighten the air cleaner wing nuts to the specified torque Torque Air Cleaner Wing Nuts 2 N m 0 2 kgf m 17 in Ib
77. f nicks or burrs 7 10 CAMSHAFT CRANKSHAFT Camshaft Tappet Camshaft Tappet Removal e Remove the crankcase cover see Crankcase Cover Re moval e Turn the crankcase up side down so that the tappets will fall away from the cam lobes e Pull the camshaft out of the crankcase e Remove the tappets A and mark them so they can be installed in their original positions during assembly Camshaft Tappet Installation e Apply engine oil to the following Tappet Journal Camshaft Journal Cam Lobe Surface Camshaft Gear e Align the punch mark A on the crankshaft gear with punch mark B on the camgear Camshaft Inspection e Check the camshaft gear A for pitting fatigue cracks burrs or an evidence of improper tooth contact x Replace the shaft if necessary e Check the top of the cam lobes B for wear burrs or un even contact x Replace the shaft if necessary Camshaft Bearing Journal Wear e Measure the height of each cam lobe x lf the cam height is less than the service limit for either lobe replace the camshaft Cam Lobe Height Service Limit Inlet Exhaust 41 45 mm 1 6319 in e Measure both camshaft journals at several points around the journal circumference x lf the journal diameter is less than the service limit re place the camshaft PTO Side Camshaft Journal Diameter Service Limit 15 99 mm 0 6295 in Flywheel Side Camshaft Journal Diameter Service Limit 15 99 mm 0 6295 in
78. g mark should appear on or near the center of the valve face e When the engine is assembled be sure to adjust the valve clearances see Valve Clearance Adjustment in this chap ter Lubrication System Oil Level Inspection e Place the engine on a level surface e Clean area around the oil gauge A before removing it e Remove the oil gauge and wipe it with a clean cloth e Insert the oil gauge into tube B following the tube bend and let it s plug firmly fit into the tube then check the oil level e The oil level should be between the ADD D and FULL C marks on the oil gauge x lf the oil level is near or below the ADD mark remove the oil filler cap E and add enough engine oil to bring oil level to the FULL mark CAUTION Do not fill above the FULL mark Excess oil will cause a smoking condition and may cause the en gine to overheat x lf the oil level is too high remove the excess oil by loos ening the drain plug A CAUTION Before starting the engine for the first time add oil The engine is shipped dry Preoil the engine to force all air from the internal oil passages and the oil filter e Fill fresh engine oil to the specified level e Run the engine at slow speed 2 minutes e Stop the engine and check the oil level e Add oil only to the FULL mark on the oil gauge Use the same type and make of oil that is already in the engine NOTE
79. ge e Clean the piston ring grooves A with a broken piston ring or other suitable tools CAUTION Be careful not to widen the ring grooves Damaged ring grooves will require piston replacement Piston Ring and Ring Groove Wear e Clean the piston see Piston Cleaning e Visually inspect the piston rings and ring grooves x If the piston rings are worn unevenly or damaged replace them x lf the ring grooves are worn unevenly or damaged re place both the piston and piston rings e Check ring grooves for wear by inserting a new ring in the proper groove at several points around the piston e Measure the clearance between the top and second rings and their grooves using a thickness gauge A x lf the piston ring groove clearance is greater than the specified value replace the piston Piston Ring Groove Clearance Service Limit Top 0 16 mm 0 0063 in Second 0 15 mm 0 0059 in NOTE OThe oil ring is a three piece assembled ring Difficult to measure the ring groove clearance and thickness visually inspect only ENGINE TOP END 5 23 Cylinder Piston e Measure the piston ring thickness A OUse a micrometer to measure at several points around the rings x If any of the measurement are less than the service limit replace the entire set of rings Piston Ring Thickness Service Limit Top Second 1 40 mm 0 055 in NOTE OWhen using new rings in a used piston check for un even
80. ge in the L1 causing a base current IB1 to flow from TR1 Then current IC1 that is amplified by TR1 flows to form the primary circuit The flywheel revolves further and the voltage that is generated in the L1 increases When the fly wheel reaches the position of the ignition timing the generated voltage overcomes the resistance R2 causing a base current IB2 to flow to transistor TR2 At that instant the current changes into collector current 1C2 which is amplified by transistor TR2 In the meantime because the internal resistance of TR2 is considerably lower than TR1 1B1 that was flowing through TR1 until then will turn into IC2 thus changing its direction to flow via TR2 In this manner base current IB1 of TR1 will not momentarily flow thus causing large current IC that was flowing in the L1 until then to stop suddenly Due to the sudden change in the current in the primary circuit a high voltage is generated in sec ondary side L2 causing spark plug to spark Handling and Maintenance Care 1 2 3 Do not bring the Igniter near fire Ignition timing is fixed and no necessary for adjusting In case of spark test pull the recoil starter grip with all your strength to obtain a required speed of the flywheel for sparking ELECTRICAL SYSTEM 8 13 Ignition System Ignition Coil Removal e Remove Radiator see Radiator Removal in the Cooling System chapter Cooling Fan see Cooling Fan Removal in the Cooling System chapter
81. hey cannot replace them Armature Inspection e Inspect the surface of the commutator A x lf it is scratched or dirty polish it with a piece of very fine emery cloth B and clean out the grooves GP11061081 8 20 ELECTRICAL SYSTEM Electric Starter System e Measure the depth of the grooves between the commu tator segments x lf the grooves are shallower than the specified limit un dercut the insulating material to the standard depth 0 5 0 8 mm 0 012 0 031 in using a thin file x If the grooves are only dirty clean them carefully Commutator Groove Depth Standard 0 5 0 8 mm 0 020 0 031 in Service Limit 0 2 mm 0 008 in Bad A Segment B Good C 0 2 mm 0 008 in limit D Mica E e Measure the commutator B outside diameter A at sev eral points x If the diameter is less than the service limit replace the armature with a new one Commutator Outside Diameter Standard 28 mm 1 102 in Service Limit 27 mm 1 06 in e Support the armature in an alignment jig at each end of the shaft as shown Position a dial indicator perpendicular to the commutator e Rotate the armature slowly and read the commutator runout x If runout is more than the service limit replace the ar mature with a new one Commutator Runout Service Limit 0 4 mm 0 016 in e Measure the armature winding resistance OSet the multimeter selector switch to the R x 1
82. iameter 11 079 mm 0 43618 in Engine Oil and Oil Filter LUBRICATION SYSTEM 6 7 CAUTION Engine operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure and accident Oil Level Inspection e Refer to the Engine Oil Level Inspection in the Periodic Maintenance chapter Oil Change e Refer to the Engine Oil Change in the Periodic Mainte nance chapter Oil Filter Removal e Refer to the Oil Filter Replacement in the Periodic Main tenance chapter Oil Filter Installation e Refer to the Oil Filter Replacement in the Periodic Main tenance chapter 6 8 LUBRICATION SYSTEM Pressurized Lubrication System The engine lubrication circuit is a pressurized system consisting of a positive displacement pump which picks up oil through a filter screen from the crankcase The oil is pumped to a replaceable oil filter cartridge through the engine s oil passages to lubricate internal components and return to the crankcase A bypass valve is incorporated in the oil filter to allow oil to circulate if the filter becomes clogged A pressure relief valve is used between the oil pump and oil filter to relieve excessive oil pressure by returning excess oil to the crankcase see Oil Flow Chart Oil Pressure Measurement e Remove the oil pressure switch A from the crankcase e Install the oil pressure gauge adapter B and oil pressure gauge C
83. iameter is more than the service limit re place the connecting rod with a new one Connecting Rod Big End Inside Diameter Service Limit 40 05 mm 1 577 in e Measure the crankpin outside diameter A OUse a micrometer to measure several points around the crankpin circumference x If the crankpin diameter is less than the service limit re place the crankshaft with a new one Crankpin Outside Diameter Service Limit 39 95 mm 1 573 in Crankshaft Runout e Measure the crankshaft runout OSet the crankshaft in a flywheel alignment jig A or on V blocks gauge OSet a dial gauge B against both bearing journals OTurn the crankshaft slowly to measure the runout The dif ference between the highest and lowest dial gauge read ings TIR is the amount of runout x If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Service Limit TIR 0 05 mm 0 002 in Crankshaft Main Journal Wear e Measure both main journals at several points around the journal circumference x lf the journal diameter is less than the service limit re place the crankshaft with a new one PTO Side Crankshaft Journal Diameter A Service Limit 39 90 mm 1 571 in Flywheel Side Crankshaft Journal Diameter B Service Limit 39 90 mm 1 571 in KG06027BS1 o ELECTRICAL SYSTEM 8 1 Electrical System Table of Contents EXPO WE 8 2 eelere TEE 8 4 Special TOON EE 8 5 Md DAG AI EE 8
84. inder Piston e When installing a piston pin snap ring compress it only enough to install it and no more e Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the notch B in the edge of the piston pin hole CAUTION Do not reuse the snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Install the piston and connecting rod so that the circle mark A on the top of the piston facing the flywheel side B Apply engine oil to the piston skirt and the cylinder bore OUsing the piston ring compressor grip A and the belt B insert the piston and connecting rod into the cylinder OLightly tap the top of the piston with a plastic mallet C to insert the piston and connecting rod into the cylinder Special Tools Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 67 79 57001 1097 Cylinder Piston ENGINE TOP END 5 21 CAUTION The connecting rod and the connecting rod big end cap are machined at the factory in the assembled state so they must be replaced together as a set e Apply engine oil to the inner surface A of the connecting rod big end B and caps C e Install the connecting rod big end caps on their original position on each connecting rod big ends e Apply a small amount of engine oil to the thread D and seating surface E of the cap bolts
85. iodic Maintenance Procedures Valve Clearance Inspection NOTE OValve clearance must be checked when the engine is cold at room temperature e Remove the rocker case see Cylinder Head Assembly Removal in the Engine Top End chapter e Place the piston at top dead center TDC of the compres sion stroke turning the crankshaft clockwise facing the fly wheel No 1 Cylinder OAlign the flywheel magnet A with No 1 ignition coil B OCheck the inlet and exhaust valves are closed completely if it is not at T D C turn the flywheel clockwise one turn 360 No 2 Cylinder OAlign the flywheel magnet A with No 2 ignition coil C Follow No 1 Cylinder alignment e Then check the clearance OUsing a thickness gauge A measure the valve clearance between the rocker arm and the valve stem end x lf the valve clearance is incorrect adjust it see Valve Clearance Adjustment in this chapter Valve Clearance when cold Inlet Exhaust 0 15 mm 0 006 in Valve Clearance Adjustment e Since the valve repairs change the valve clearance ad just the valve clearance to the specification e Assemble the cylinder head and install the cylinder head assembly on the block see Cylinder Head Assembly In stallation in the Engine Top End chapter e Turn the crankshaft proper direction until the piston is at TDC of the compression stroke described above e Loosen the nut C and valve clearance adjusting bolts B e Insert
86. ir cleaner model 1 Replace air cleaner primary element Heavy duty air cleaner model 1 Check air cleaner secondary element Heavy duty air cleaner model 1 Replace air cleaner secondary element Heavy duty air cleaner model 1 Clean combustion chambers Check and adjust valve clearance PERIODIC MAINTENANCE 2 3 Periodic Maintenance Chart INTERVAL First Every Every Every Every Every Every Every Daily 8 hr 25 100 200 250 300 400 500 OPERATION hr hr hr hr hr hr hr Clean and lap valve seating A surface x Inspect radiator and hoses e Change coolant e 1 Service more frequently under dusty conditions x These items must be performed with the proper tools See your authorized Kawasaki Engine Dealer for service unless you have the proper equipment and mechanical proficiency 2 4 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners and the parts requiring use of a non permanent locking agent or liquid gasket Letters used in the Remarks column mean L Apply a non permanent locking agent to the threads Lh Left hand threads O Apply engine oil S Tighten the fasteners following the specified sequence SS Apply silicone sealant Torque Fastener Me kam SO Remarks Fuel System Carburetor and Inlet Pipe Mounting Bo
87. l Bearing Inside Diameter Service Limit 40 01 mm 1 575 in CAMSHAFT CRANKSHAFT 7 9 Breather The function of the breather is to create a vacuum in the crankcase which prevents oil from being forced out of the engine through the piston rings oil seals or gaskets The breather has a reed valve C which limits the direction of air flow caused by the piston moving up and down Air can flow out of the crankcase but the one way reed valve blocks return flow It thus maintains a vacuum in the crankcase Oil laden air in the crankcase passes through the reed valve and expand into the breather chamber Here most oil separates from the air and drains back to the crankcase The air passes through a maze E and vents to the air cleaner F Drain Hole D Breather Valve Removal e Remove the bolts A and breather chamber cover B e Unscrew the mounting screw A and remove the back plate B and reed valve Breather Valve Installation e Be sure the drain hole does not accumulate with slugges before installing the breather valve e Align center of the valve seat with center of the reed valve and back plate then tighten the mounting screw Breather Valve Inspection e Inspect the reed valve for breakage hair cracks or distor tion replace it if necessary e Inspect the back plate for damage or rough contact sur face replace it if necessary e Inspect the valve seating surface The surface should be free o
88. l in position and lightly tap the ball with a suitable tools to form a perfect seat e Measure free length A of the spring with a vernier caliper x If the free length of the spring is less than the service limit replace the spring Relief Valve Spring Free Length Service Limit 19 50 mm 0 7677 in HO P Oil Screen Filter LUBRICATION SYSTEM 6 13 Oil Screen Filter Removal e Remove the crankcase cover see Crankcase Cover Re moval in the Camshaft Crankcase chapter e Remove the oil pump parts assembly see Oil Pump Re lief Valve Removal in this chapter e Remove the oil screen filter A Oil Screen Filter Cleaning and Inspection e Clean the oil screen A with high flash point solvent and remove any particles stuck to it A WARNING Clean the screen in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents NOTE OWhile cleaning the screen check for any metal particles that might indicate internal engine damage e Check the screen carefully for any damage holes and broken wire x If the screen is damaged replace the oil screen filter B CAMSHAFT CRANKSHAFT 7 1 Camshaft Crankshaft Table of Contents EXPlOded WE 7 2 eene de EE 7 4 ell EE 7 5 A eege ee EE Coos bandla esse 7 6 Crankcase Cover Removal isiicin arira a ia iaia
89. l the compression gauge stops rising the compression reading obtainable e Repeat the measurement to the other cylinder Measurement Condition Valve Clearance Inlet Exhaust 0 15 mm 0 006 in Carburetor with full open throttle valve Engine Oil Temperature 50 60 C 122 140 F Cranking rpm at time 480 rpm 5 seconds Cylinder Compression MIN 682 kPa 99 psi 5 10 ENGINE TOP END Cylinder Head x If the compression is higher than the specified value the piston rings cylinder and valves are probably in good con dition If the compression is too high check the following 1 Carbon build up on the piston head and cylinder head clean off any carbon on the piston head and cylinder head 2 Cylinder head gasket use only the proper gasket The use of a gasket of incorrect thickness will change the compression 3 Valve guides and piston rings rapid carbon accumu lation in the combustion chamber may be caused worn valve guides and or worn piston oil rings This may be indicated by white exhaust smoke x If cylinder compression is lower than the MIN check the following 1 Gas leakage around the cylinder head replace the damaged gasket and check the cylinder head warp Condition of the valve seating Valve clearance Piston cylinder wear piston seizure Piston ring piston ring groove oye Cylinder Head Assembly Removal e Remove Radiator see Cooling System chapter Air Cleaner and Car
90. le carefully spread the ring opening with your thumbs and then push up on the oppo site side of the ring A to remove it Remove the 3 piece oil ring with your thumbs in the same manner 6E16060651 Piston Installation e Install the expander A in the piston oil ring groove so that the expander ends B touch together never overlap e Install the upper and lower steel rails There is no UP or Down to the rails They can be installed either way KE06045BS51 e Do not mix up the top and second rings e Install the second ring A so that the R mark B face up e Install the top ring C so that the R mark D face up e The rings should turn freely in the grooves Piston Head E KEO6053BS1 o e Align the piston and rings with the piston ring end gap as shown Circle Marks A Top Ring End Gap Upper Steel Rail End Gap B 30 45 C Second Ring End Gap Lower Steel Rail End Gap D C KE06054BS1 o e Apply engine oil to the piston pins e Assemble the pistons onto the connecting rods as follow No 1 Cyl piston align the circle mark on the piston head with the raised letters K Mark on the connecting rod No 2 Cyl piston align the circle mark on the piston head with opposite K mark on the connecting rod A No 1 Cyl Piston B No 2 Cyl Piston C Circle Marks D K Mark E Opposite K Mark KEO6052BS1 o 5 20 ENGINE TOP END Cyl
91. ling fan see Cooling Fan Removal in this chapter e Unscrew the thermostat cover bolts A and remove the cover B e Take off the thermostat C NOTE OWith the thermostat installed the jiggle valve may be positioned up side of the thermostat when installing e Installation is reversed of removal OReplace the gasket with a new one OTighten the bolts to the specified torque Torque Thermostat Cover Bolts 6 N m 0 6 kgf m 53 in lb Thermostat Inspection e Remove the thermostat and check the jiggle valve A for sticking or binding on the flange B due to accumulation of arust scale or lime Clean up the valve to ensure free movement of the valve C if necessary e Inspect the thermostat valve A at room temperature x lf the valve is open replace the valve with a new one e To check valve opening temperature suspend the ther mostat and an accurate thermometer B in a container filled with a water e Place the container over a source of heat and gradually raise the temperature of the water while stirring the water gently OWatch the valve The valve should begin to open at the temperature specified Olt should be fully opened to 7 mm 0 28 in or more at the temperature specified Thermostat Valve Specification Begin Opening 80 84 C 176 183 F Full Open 95 C 203 F The thermostat and thermometer must not touch the con tainer sides x If the thermostat fails any of these check replace it
92. lts and Nuts 1 2 104 mb Standard Air Cleaner Model Carburetor and Inlet Pipe Mounting Bolts and Nuts 1 2 104 mb Heavy Duty Air Cleaner Model Inlet Manifold Mounting Bolts 0 6 53 in lb S Pilot Jets 0 17 15 in lb Main Jets 0 07 6 in lb Float Chamber Mounting Screws 0 20 17 in lb Fuel Shut Off Solenoid Valve 0 71 61 in lb Drain Screw 0 13 11 ml Air Cleaner Wing Nuts 0 2 17 in lb Air Cleaner Tube Clamps 0 2 17 in lb Governor Arm Clamp Nut 0 8 69 in lb Cooling System Radiator Hose Clamp Bolts 0 13 12 in lb Water Pump Cover Mounting Bolts M6 1 0 87 in lb S Water Pump Cover Mounting Bolts M8 2 2 17 S Impeller Bolt 1 0 87 in lb Lh Thermo Switch 2 9 21 SS Thermostat Cover Bolts 0 6 53 in lb Radiator Mounting Bolts 0 6 53 mb Coolant Drain Plug 1 5 11 Engine Top End Rocker Arm Bracket Mounting Bolts 2 2 17 Valve Clearance Adjusting Nuts 1 1 96 in lb Connecting Rod Big End Cap Bolts 1 0 87 in lb O Exhaust Pipe Flange Nuts 2 0 15 Cylinder Head Bolts New 3 3 24 S Cylinder Head Bolts Reuse 2 5 18 S Muffler Bracket Bolts 2 0 15 Lubrication System Oil Drain Plugs 6 9 0 70 61 in Ib Oil Pressure Switch 9 8 1 0 87 in lb SS Camshaft Crankshaft Crankcase Cover Bolts M8 2 2 17 S PERIODIC MAINTENANCE 2 5 Torque and Locking Agent Remarks N m_ kgf m ft Ib Connecting Rod Big End Cap Bolts 9 8 1 0 87 in lb O Electrical System Flywheel Bolt 56 5 7 41 Stator Coil Screws 3 4 0 35 30 in lb Igniti
93. lts and tighten them Oil Pump Relief Valve Inspection e Remove the oil pump see Oil Pump Relief Valve Re moval in this chapter e Visually inspect the pump gear outer and inner rotor and cover plate x lf there is any damage or uneven wear replace them OCheck the clearance A between the inner and outer rotor with a feeler gauge Measure the clearance between the high point of the inner rotor and the high point of the outer rotor x If the measurement exceed the service limit replace the rotors as a set Inner and Outer Rotor Clearance Service Limit 0 21 mm 0 0083 in KFO7006BS1 o LUBRICATION SYSTEM 6 11 Oil Pump and Relief Valve e Measure the outside diameter A of the outer rotor with a micrometer at several points x If the rotor diameter is less than the service limit replace both the inner and outer rotor Outer Rotor Outside Diameter Service Limit 40 470 mm 1 5933 in e Measure the thickness B of the outer rotor with a mi crometer at several points x If the rotor thickness is less than the service limit replace both the inner and outer rotor Outer Rotor Thickness Service Limit 9 94 mm 0 391 in e Measure the inside diameter A of the pump housing with a inside micrometer at several points x If the inside diameter is more than the service limit re place the crankcase cover Pump Housing Inside Diameter Service Limit 40 801 mm 1 6063 in e Measu
94. n at 95 C 203 F Thermo Switch Detect Temperature 108 114 C 226 237 F A permanent type of antifreeze is not installed in the cooling system when shipped COOLING SYSTEM 4 5 Sealant Kawasaki Bond Silicone Sealant 56019 120 gt ST560120ST 4 6 COOLING SYSTEM Cooling System This engine is equipped with a highly efficient pressurized cooling system using a thermostat to maintain an optimum operating temperature Coolant bypasses the closed ther mostat when cold until operating temperature is attained causing the engine to warm up more quickly If the coolant temperature becomes too high a thermo switch on the en gine activates the coolant warning lamp to alert the operator or cooling problem Reserve Tank A Radiator B Cooling Fan C Thermo Switch D Thermostat E Bypass Tube F Water Pump Impeller G Inlet Manifold H SNA dem Hot Coolant lt 3 Cold Coolant KDO4000BW2 C A WARNING Prior to disassembly of cooling system parts radi ator pump sensor etc wait until the coolant cools down and then drain the coolant CAUTION After assembling and filling the system with a coolant purge any air from the system Coolant COOLING SYSTEM 4 7 Coolant Deterioration e Visually inspect the coolant in the radiator Olf whitish cotton like wafts are observed aluminum parts in the cooling sys
95. n place on the crankcase cover as shown in the figure B A e Press in the dowel pins A into the crankcase cover B 5 mm 0 20 in C KG04031BS1 o e Check to see that the O rings B are in place on the crankcase as shown in the figure e Apply sealant bead C wide 1 2 mm to the mating surface D of the crankcase cover as shown in the figure Sealant Kawasaki Bond 92104 1064 CAUTION Do not get the sealant into the oil line hole E on the crankcase or crankcase cover KG04029BS2 C 7 8 CAMSHAFT CRANKSHAFT Crankcase e Install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence shown Torque Crankcase Cover Bolts 22 N m 2 2 kgf m 17 ft lb ONote the position of different length of the bolts ODo not turn one screw down completely before the others as it may cause the crankcase cover to warp Inspection e Measure the inside diameter A of the PTO shaft bearing on the crankcase cover at several points This bearing is not replaceable Replace the crankcase cover if the inside diameter is more than the service limit PTO Shaft Bearing Inside Diameter Service Limit 40 04 mm 1 576 in e Measure the inside diameter A of the crankshaft journal bearing on the crankcase at several points This bearing is not replaceable Replace the journal bushing if the in side diameter is more than the service limit Crankshaft Journa
96. n deteriorated on the inside and still appear to be in good condition on the outside Radiator Hose Installation Notes e Install the radiator hoses being careful to follow bending direction see in the figures Avoid sharp bending kink ing flatting or twisting Upper Hose Clamp A Radiator Hose Thermostat Side B Radiator Hose Starter Motor Side C Lower Hose Clamp D NOTE OLocate the hose clamps properly over the connections A pressurized cooling system will blow a hose that is not installed properly Tighten the hose clamps securely Torque Radiator Hose Clamp Bolts 1 3 N m 0 13 kgf m 12 in Ib KDO8002BS1 o COOLING SYSTEM 4 15 Cooling Fan The only service on the cooling fan is to be sure the fan blades are not deformed and the blade tips are far enough from the air duct to not strike the duct Cooling Fan Removal e Remove Radiator see Radiator Removal in this chapter OUnscrew the mounting bolts A and remove the cooling fan B KDO9B014 F Cooling Fan Installation e Install the cooling fan as AISHIN raised lettering A on the fan boss facing toward the radiator Cooling Fan Inspection e Be sure the fan blades are straight Deformed blades reduce the cooling system efficiency and throw the fan out of balance 4 16 COOLING SYSTEM Thermostat Thermostat Removal and Installation e Remove the radiator see Radiator Removal in this chap ter e Remove the coo
97. n the radiator after the engine cools down x If the coolant level is low add coolant up to the filler neck bottom A e Install the cap Visual Leak Inspection Any time the system slowly loses water inspect for leaks Small leaks may appear only a rust corrosion or stain due to evaporation Watch for these trouble spots e Check the water pump housing drainage outlet passage A for coolant leaks x lf the mechanical seal is damaged the coolant leaks through the seal and drain through the passage Replace the mechanical seal B x If there are no apparent leaks pressure test the system Cooling System Pressure Testing Air pressure leakage tester can help locate external leaks but they cannot depended upon to locate small combustion leaks CAUTION During pressure testing do not exceed the pres sure for which the system is designed The maxi mum pressure is 102 7 kPa 1 05 kgf cm 14 9 psi KDO5000BS1 o Coolant COOLING SYSTEM 4 9 e Remove the radiator cap and install a cooling system pressure tester A on the radiator filler neck e Wet the cap sealing surfaces with water or coolant to pre vent pressure leaks e Build up pressure in the system carefully until the pres sure reaches 60 kPa 0 61 kgf cm 8 7 psi e Watch the pressure gauge for at least 6 seconds If the pressure holds steady the system is all right e Remove the pressure tester replenish the coolant
98. nsumption is excessive High fuel level in carb float chamber including overflow High idling R P M Choke partially closed Excessively backed off carbu retor pilot screw Worn piston piston rings Stuck piston Worn cylinder bore lnsufficient cyl head tightness Faulty valve seat contact Plunge up of valve Wrong valve timing Broken valve spring Stuck valve Is compression sufficient Plugged oil ring groove High oil level Worn valve stems and valve guide GO leakage along governor shaft GO leakage from oil seal GOU leakage from mounting surface GOU leakage from drain plug Clogged breather valve Drain back hole in breather chamber plugged lncorrect oil viscosity Worn piston rings Stuck piston rings Worn cylinder bore Broken piston ring Engine backfires Engine knocks Loose carb or inlet manifold Loose cyl head or leaking head gasket Burned or sticking intake valve Faulty ignition coil Carb not properly adjusted Stale fuel Excessive carbon deposit in engine Excessive engine load Engine overheating Faulty ignition coil Adjust Adjust Open choke Adjust Replace Clean or replace Bore or replace Retighten Lap Adjust valve clearance Adjust Replace Clean or replace Clean Adjust Replace Replace Replace Replace gasket Retighten or replace gasket Clean Clean C
99. nto place in the air cleaner body e Install the cap and fasten the two clips Element Cleaning and Inspection e Refer to the Element Cleaning and Inspection in the Pe riodic Maintenance chapter Cleaner Body Removal e Remove the elements see Element Removal in this chapter e Loosen the hose clamps A and remove the hose D e Remove Bolts and Washers B Inlet Pipe Cover C e Loosen the bolt A and remove the bracket B and air cleaner body C FUEL SYSTEM 3 27 Air Cleaner Heavy Duty Type e Loosen the bolts A and remove the bracket B e Loosen the bolts B and nuts C and remove the inlet pipe A Cleaner Body Installation e Replace the inlet pipe gasket with new ones e Clean the mating surfaces of the carburetor and inlet pipe e Install the inlet pipe and connect the solenoid valve lead terminal e Tighten the mounting bolts and nuts Torque Carburetor and Inlet Pipe Mounting Bolts and Nuts 12 N m 1 2 kgf m 104 in Ib e Install the removed parts NOTE OSet the air cleaner body onto the bracket so that the air inlet duct is facing upward e Tighten the air cleaner tube clamps Torque Air Cleaner Tube Clamps 2 N m 0 2 kgf m 17 in Ib Housing Inspection e Refer to the Housing Inspection in the Periodic Mainte nance chapter COOLING SYSTEM 4 1 Cooling System Table of Contents E leie e WT 4 2 eelere TEE 4 4 OA TEE 4 5 COQUINRO Rn EE 4
100. ompression MIN Cylinder head warp 682 kPa 99 psi MIN 0 03 mm 0 001 in Valves Valve head thickness Inlet Exhaust Valve stem bend Inlet Exhaust Valve stem diameter Inlet Exhaust Valve guide inside diameter Inlet Exhaust Valve spring free length Inlet Exhaust Rocker arm push rod runout Inlet Exhaust Rocker arm collar outside diameter Inlet Exhaust Rocker arm bearing inside diameter Inlet Exhaust Cylinder Piston Piston ring groove clearance Top Second Piston ring thickness Top Second Piston ring end gap Top Second Oil Piston pin outside diameter Piston pin hole inside diameter Connecting rod small end inside diameter Cylinder inside diameter Piston outside diameter Cylinder bore out round 0 35 mm 0 014 in 0 05 mm 0 002 in 6 94 mm 0 2730 in 7 08 mm 0 279 in 32 9 mm 1 30 in 0 5 mm 0 02 in 10 914 mm 0 4297 in 11 132 mm 0 4382 in 0 16 mm 0 0063 in 0 15 mm 0 0059 in 1 40 mm 0 055 in 0 7 mm 0 03 in 1 0 mm 0 04 in 15 96 mm 0 628 in 16 09 mm 0 6335 in 16 06 mm 0 6323 in 75 30 mm 2 965 in 74 98 mm 2 952 in 0 056 mm 0 0022 in Specifications ENGINE TOP END 5 7 Item Standard Valve clearance Inlet Exhaust Valve seating surface angle Inlet Exhaust Valve seating surface width Inlet Exhaust Valves guide inside diameter Inlet Exhaust Cylinder bore diameter Standard cylinder 0
101. on Coil Mounting Bolts 3 4 0 35 30 in lb S Spark Plugs 25 2 5 18 Thermo Switch 28 2 8 21 SS Oil Pressure Switch 10 1 0 87 in lb Ss Starter Motor Mounting Bolts 15 1 5 11 Regulator Bolts 6 0 6 53 in lb The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners Threads Diameter mm ft lb 17 in lb 30 in lb 52 in lb 11 2 6 PERIODIC MAINTENANCE Specifications Item Fuel System Idle Speed 1 Low Idle Speed High Idle Speed Air Cleaner Type Pre Cleaner Two Stage Cleaner Cooling System Coolant Type Color Mixed Ratio Freezing Point Total Amount Engine Top End Valve Clearance Inlet Exhaust Inlet Exhaust Inlet Exhaust Standard FD680V FD731V 1 550 r min rpm 3 600 r min rpm Dual stage filtration system Foam element Paper element Heavy duty air cleaner type Primary element Secondary element Valve Seating Surface Angle Valve Seating Surface Width Permanent type of antifreeze for aluminum engine and radiator Green 50 35 C 31 F 2 7 L 2 9 US qt 0 15 mm 0 006 in 45 0 8 1 4 mm 0 031 0 055 in 1 1 1 6 mm 0 043 0 063 in Lubrication System Engine Oil Type Visc
102. orrect Replace Clean or replace Bore or replace Replace Tighten Tighten Replace Replace Adjust Change Clean Adjust See engine loss power Replace 9 6 TROUBLESHOOTING Engine Troubleshooting Guide Coolant leakage Deleterious radiator hose 0 Mechanical failure of radiator 0 Loose cylinder head O Cracked or porous casting Loose stud bolts and cap screw Engine overheating Damaged water pump sealing Improperly installed gasket O Mulfunction radiator cap Replace Repair or Replace Tighten Replace Repair See engine loss power Replace Correct or Replace Replace Starter Motor Troubleshooting Guide TROUBLESHOOTING 9 7 1 Disconnect spark plug cap and ground the cap terminal 2 Turn engine switch to START position and check con dition test CAUTION A WARNING Engine may be cranked in this test Do not touch any rotating parts of engine and equipment during If starter does not stop by engine switch OFF dis connect negative lead from battery as soon as possible STARTER DOES NOT ROTATE Is click sound from solenoid switch STARTER ROTATES BUT SLOW NO gt O Faulty battery 6 Faulty leads or connection OMelted fuse Faulty engine switch Faulty solenoid switch H Charge or replace Repair or replace H Replace Repair or replace Replace Weak
103. osity Capacity Level Electrical System Spark Plug Gap SF SG SH or SJ class SAE 40 SAE 30 SAE 10W 30 SAE 10W 40 or SAE 5W 20 2 0 L 2 1 US qt When filter is not removed 2 3 L 2 4 US qt When filter is removed Between ADD and FULL marks 0 75 mm 0 30 in 1 Idle speeds may vary depending on each equipment Refer to the equipment specification PERIODIC MAINTENANCE 2 7 Special Tools and Sealant Valve Seat Cutter 45 35 Valve Seat Cutter 45 630 57001 1116 57001 1187 ST5711168T ST571187ST Valve Seat Cutter 32 630 Valve Seat Cutter 32 33 57001 1120 57001 1199 ST5711208T ST5711998T Valve Seat Cutter Holder 7 Oil Filter Wrench 57001 1126 57001 1249 8757112697 ST5712498T Valve Seat Cutter Holder Bar Kawasaki Bond Silicone Sealant 57001 1128 56019 120 gt ST5711288T ST560120ST 2 8 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System NOTE OHigh and low idle speeds may vary depending on the equipment on which the engine is used Refer to the equipment specification High Idle Speed Adjustment NOTE OHigh idle speed adjustment should be made after the idle speed adjustment is performed CAUTION Do not adjust high idle speed with the air cleaner removed e Start and warm up the engine thoroughly A WARNING Always
104. r Oil is separated from the gasses while passing through the inside of the breather chamber from the crankcase and then returned to the bottom of the crankcase 2 Exhaust Emission Control System The exhaust emission control system applied to this engine consists of a carburetor and an ignition system having optimum ignition timing characteristics The carburetor has been calibrated to provide lean air fuel mixture characteristics and opti mum fuel economy with a suitable air cleaner and exhaust system TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED Federal law and California State law prohibits the following acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new engine for the purpose of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the engine after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Do not tamper with the original emission related part e Carburetor and internal parts e Spark plugs e Magneto or electronic ignition system e Fuel filter element e Air cleaner elements e Crankcase e Cylinder heads e Breather chamber and internal parts e Inlet pipe and tube Foreword This manual i
105. rburetor insulator and inlet manifold and fit new gaskets OTake care not to bend the throttle and choke link rods during installation Make sure the link spring around the throttle link rod is inplace and that it pulls the governor arm and carburetor throttle shaft lever toward each other 3 16 FUEL SYSTEM Carburetor Standard Type Air Cleaner Inlet Manifold A Gaskets B Insulator C Carburetor D Gasket E Inlet Pipe F Heavy Duty Type Air Cleaner Inlet Manifold A Gaskets B Insulator C Carburetor D Gaskets E Bracket F Cover G e Connect the solenoid valve lead terminal e Adjust Carburetor Pilot Screw Idle Speed see Low High Idle Speed Adjustment in the Periodic Maintenance chapter e Install the removed parts KCOSO88BS2 C KC05089BS2 C Carburetor FUEL SYSTEM 3 17 Carburetor Disassembly Assembly e Refer to the illustration shown for disassembly and as sembly e There are several passage plugs ball plugs in the car buretor body Do not remove e Before disassembly mark the out side of choke valve for assembling it Screw Cover Gasket Pilot Screw Assy Choke Valve Assy Pilot Jet Pilot Jet Screw Float Assy 10 Main Jet L 11 Main Jet R 12 Float Chamber Assy OONOABRWDN e Replace the pilot screw in accordance with the following procedure if necessary OCarefully mark the position of the
106. re the depth B of the pump housing with a depth micrometer at several points lf any of measurement is more than the service limit re place the crankcase cover Pump Housing Depth Service Limit 10 230 mm 0 4028 in e Measure the outside A diameter of the pump shaft with a micrometer at several points x If the diameter is less than the service limit replace the pump shaft Pump Shaft Outside Diameter Service Limit 10 923 mm 0 4300 in e Measurer the inside diameter A of the pump shaft bear ing in the crankcase cover with a inside micrometer at several points x If the inside diameter is more than the service limit replace the crankcase cover Pump Shaft Bearing Inside Diameter Service Limit 11 079 mm 0 43618 in 6 12 LUBRICATION SYSTEM Oil Pump and Relief Valve e Visually inspect the relief valve spring steel ball and valve seat in the crankcase cover lf any rough spots are found during above inspection wash the valve clean with a high flash point solvent and blow out any foreign particles that may be in the valve with compressed air A WARNING Clean the parts in a well ventilated area and take care that there is no spark or flame anywhere near the working areas Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents x If cleaning does not solve the problem replace the relief valve parts x f necessary put the bal
107. rfaces should be smooth and free of burrs and nicks Replace the gasket if necessary e Turn the throttle and choke shafts to check that the throttle and choke butterfly valves move smoothly x If the valves do not move smoothly replace the carburetor body and or throttle shaft and choke shaft assembly e Check that the gasket on the float chamber x If the gasket is not in good condition replace it e Check the other parts of the carburetor for wear or dam age Replace the part if necessary e Clean and check the float level as follows CAUTION Do not push down on the float during float level checking e With the float A assembly installed onto the carburetor body B hold the carburetor upside down at an eye level Gently support the float with a finger and bring it down slowly so that the float arm tab C just touches the float valve D The float arm surface E should be parallel G with the carburetor body mating surfaces F x If the float position is not correct bend the tab as required for correct adjustment e Inspect the float valve for excessive wear or damage The tip should be smooth without any grooves scratches or tears The rod at the other end of the needle should move smoothly when push in and released x If either the valve or the seat is worn or damaged replace the float assembly and carburetor body as a set KCGO5011BS1 C 3 20 FUEL SYSTEM Carburetor e Inspect th
108. rly adjusted Too much oil in crankcase Worn piston piston rings Worn cylinder bore O Defective breather valve Correct Change Replace Replace Replace Clean Clean Clean Adjust Adjust level H Replace H Bore or replace H Replace See Engine Starts Hard O Spark plug fouled pitted or gapped incorrectly Replace or adjust system lack of fuel Entry of dust or water into fuel pipe or fuel filter Air or vapour lock in fuel line Plugged air vent of fuel tank cap Plugged air fuel passes in carb Too little opening of carb pilot screw Carb not properly adjusted O Carb flange leaking at gasket Worn carb body and throttle shaft Clean Clean Clean Clean Correct Adjust Tighten or replace Replace 9 4 TROUBLESHOOTING Engine Troubleshooting Guide Problem in the governor system Engine malfunctions at high speed lncorrect linkage adjustment Faulty governor spring Governor ass y malfunctioning governor Correct Replace Check Is revolution fluctuation of relatively large period produced when a load is applied YES Plugged air hole in tank cap Entry of dust and air into fuel filter or fuel pipe Clean Clean Engine malfunctions at low speed Remove spark pl
109. rmostat Inspection oooooooooconnccoonconccooncooncnn nono nonononnnnnnnnnnnnnnnnnnnnnnnnnn nn nono nn nono nnnnnnnnnnnnnnos 4 16 Thermo Wii O A ad 4 17 Thermo Switch Removal and Installaton 4 17 Thefmo Switch Aspect Oi ageweiht 4 17 4 2 COOLING SYSTEM Exploded View pence 0 8 E COOLING SYSTEM 4 3 Exploded View Fastener Remarks 1 Radiator Hose Clamp Bolts E 12 in lb 2 Water Pump Cover Mounting Bolts M6 87 in lb 3 Water Pump Cover Mounting Bolts M8 16 4 Impeller Bolt 87 in lb 5 Thermo Switch 28 2 9 21 SS 6 Thermostat Cover Bolts 6 0 6 53 in lb 7 Radiator Mounting Bolts 6 0 6 53 in lb 8 Coolant Drain Plug 15 1 5 11 G Apply grease Lh Left hand threads A Replacement Parts S Follow the specific tightening sequence SS Apply silicone sealant A Optional Parts 4 4 COOLING SYSTEM Specifications Item Standard Coolant Type Color Mixed Ratio Freezing Point Total Amount Radiator Cap Relief Pressure Pressure Valve Positive Vacuum Valve Negative Permanent type of antifreeze for aluminum engine and radiator Green 50 solution of ethylene glycol 35 C 31 F 2 7 L 2 9 US qt 73 3 102 7 kPa 0 75 1 05 kgf cm 10 6 14 9 psi 4 90 kPa 0 050 kgf cm 0 71 psi Thermostat Valve Openning Temperature Valve Full Openning Lift 80 84 C 176 183 F not less than 7 mm 0 28 i
110. rter Solenoid and Circuit Test section before starting following procedures e Remove the starter motor e Hold the starter motor with a vice CAUTION Be careful not to deform the starter motor body when holding it with a vice e Connect the first jumper cable to the battery terminal and the other end of the cable to the starter motor terminal on the solenoid as shown e Connect the second jumper cable to the battery termi nal e Touch the switch intermittently for one second intervals e The pinion should rotate freely x If the pinion does not rotate freely replace the starter mo tor ELECTRICAL SYSTEM 8 17 Electric Starter System Starter Motor Disassembly e Remove the lead A from the starter motor to the sole noid e Unscrew the mounting nuts A and remove the solenoid assembly B e Remove the through bolts A e Pull the rubber insert B from the starter motor and re move the pinion gear cover C as shown e Slip the actuating arm D from the pinion gear e Pull the armature A from the yoke B e Separate the front stopper A and rear stopper C each other and remove the front stopper to the left side e Push the rear stopper down the shaft and remove the snap ring B e Pull the rear stopper and pinion gear D from the arma ture shaft 8 18 ELECTRICAL SYSTEM Electric Starter System e Gently pull the end cover B from the yoke and r
111. s designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts as to his ability to do the work all ad justments 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 engine e Follow the Periodic Maintenance Chart in the Service Manual e Be alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki 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 r
112. set the flywheel at T D C of power stroke each cylinder OWhen setting the flywheel at T D C of 1 cylinder align the center of the flywheel magnet A with No 1 ignition coil B If it is not at T D C turn the flywheel clockwise one turn 360 OWhen setting the flywheel at T D C of 2 cylinder turn the flywheel magnet A clockwise from position at T D C of 1 cylinder to at No 2 ignition coil C If it is not at T D C turn the flywheel clockwise with one turn 360 e Clean the mating surfaces of the cylinder heads and cylin der e Install the knock pins on the cylinder e Put a new gaskets A with its fire ring facing to the crankcase side and the cylinder head assemblies on each cylinder then let the cylinder heads with push rods aligned under the rocker arms see Valve Mechanism Removal Installation Push Rod Installation NOTE OAs the head gaskets are coated with sealing agents be careful not to injure the surfaces of them e Install the head bolts e Tighten the head bolts following the tightening sequence as shown Torque Cylinder Head Bolts New 32 N m 3 3 kgf m 24 ft Ib Cylinder Head Bolt Reuse 25 N m 2 5 kgf m 18 ft lb CAUTION A torque wrench must be used to prevent loose or overtight the head bolts which may result in warp ing of the cylinder head KE04021BS1 o 5 12 ENGINE TOP END Cylinder Head Push Rod Installation e When installing the push rod se
113. should be smooth and free of burrs and nicks e Check the other parts for wear or damage replace the parts if necessary x lf the mechanical seal is damaged the coolant leaks through the seal and drain through the drainage outlet passage x lf the oil seal is damaged the engine oil drain through the drainage passage x lf the mechanical seal parts are damaged replace the seal as a set e Visually check the impeller x If the surface is corroded or if the blades are damaged replace all internal pump parts 4 12 COOLING SYSTEM Radiator Radiator Removal e For FD731D Model note the following OClear the hook A ORemove the radiator cover B by sliding the cover as shown A WARNING Always allow the engine to cool before removing the radiator cap Then remove the cap slowly and carefully to avoid a possible fast discharge of hot coolant which could cause severe burns e Remove the radiator cap and drain the coolant in the ra diator see Coolant Draining in this chaoter e Loosen the hose clamps A and disconnect the radiator hoses B e Unscrew the radiator mounting bolts C e Remove the radiator D pulling toward you and up Radiator Installation e Installation is the reverse of removal Torque Radiator Mounting Bolts 6 N m 0 6 kgf m 53 in Ib Radiator Inspection e Check the radiator core x lf the corrugated fins are deformed carefully straighten them with the blade of thin
114. t of high temperature grease into the oil seal on the crankcase e Apply engine oil to the journal and bearing e Carefully insert the crankshaft flywheel end into the main bearing and oil seal in the crankcase Cleaning Inspection e After removing clean the crankshaft and connecting rods with a high flash point solvent and dry them with com pressed air e Inspect the teeth of the crankshaft gear for pitting fatigue cracks burrs and evidence of improper tooth contact Replace the gear if necessary e Inspect the crankshaft and connecting rods especially at the bearing surfaces for wear scratches evidence of im proper contact or other damages x Replace them if necessary CAMSHAFT CRANKSHAFT 7 13 Crankshaft Connecting Rod Connecting Rod Bend Twist e Measure the connecting rod bend OSelect an arbor of the same diameter as the connecting rod big end and insert the arbor through the connecting rod big end OSelect an arbor of the same diameter as the piston pin and at least 100 mm 3 94 in long and insert the arbor through the connecting rod small end OOn a surface plate set the big end arbor on V blocks OWith the connecting rod held vertically use a height gauge to measure the difference in the height of the small end arbor above the surface plate over a 100 mm length to determine the amount of connecting rod bend x If connecting rod bend exceeds the service limit the con necting rod must be replac
115. t the flywheel at T D C of power stroke each cylinder see Cylinder head Assembly Installation e Install the push rods in their original positions on each cylinder OTo install the push rod in a correct position on the tappet insert the push rod so end of the push rod is sliding down along inside wall of the crankcase and position the push rod end on the tappet e Check both intake and exhaust push rods on each cylin der are lowest position on the cam lobes if not turn the flywheel clockwise one turn 360 e Be sure the end of the push rods are correctly seated on the tappets A Push Rods B Tappets C Lowest Cam Lobes D Inside Walls E Sliding Down Push Rod Inspection e Place the rocker arm push rod in V blocks that are as far apart as possible and set a dial gauge A on the rod at a point halfway between the blocks Turn the rod to measure the runout The difference between highest and the lowest dial readings is the amount of runout x If the runout exceeds the service limit replace the rod Rocker Arm Push Rod Runout Service Limit Inlet Exhaust 0 5 mm 0 02 in Valve Mechanism Removal Installation e Remove the cylinder head assembly see Cylinder Head Assembly Removal NOTE OWhen removing the valve mechanism parts note their position so that they may be reinstalled in their original position during assembly e Remove Nuts A Bolts B Washers C Collars D Rocker Arms E
116. tem are corroded If the coolant is brown iron or steel parts are rusting In either case flush the cooling system Olf the coolant gives off an abnormal smell when changing check for a cooling system leak It may be caused by exhaust gas leaking in to the cooling system Coolant Level Inspection e Put the engine on a level surface e Remove the radiator cap turning it counterclockwise and check the coolant level in the radiator A WARNING Always allow the engine to cool before removing the radiator cap Then remove the cap slowly and carefully to avoid a possible fast discharge of hot coolant which could cause severe burns e Coolant level must be maintained a level of the filler neck bottom A x If the amount of the coolant is insufficient fill the radiator up to the bottom of the radiator filler neck A with the coolant and install the cap turning it clockwise CAUTION For refilling add the specified mixture of coolant and soft water Adding water alone dilutes the coolant and degrades its anticorrosion properties The diluted coolant can attack the aluminum engine parts In an emergency soft water can be added But the diluted coolant must be returned to the correct mixture ratio within a few days If coolant must be added often there is probably leakage in the cooling system Check the system for leaks see Visual Leak Inspection and Pressure Testing Coolant Draining The coolant should be
117. tep 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 illustration 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 GENERAL INFORMATION 1 1 General Information Table of Contents Before SEV ICING DEE 1 2 Model Identttcatton cece cece cece cece eee ee ee ceee eee ee ee ee eeeaee eae eee eae eee seed seeeseeeseeeseeeeeeeeeeeeeeeeees 1 4 General Specific EE 1 5 1 2 GENERAL INFORMATION Before Servicing Before starting to service the engine carefully read the applicable section to eliminate unnecessary work Photographs diagrams notes cautions warnings and detailed descriptions have been in cluded wherever necessary Nevertheless even a detailed account has limitations a certain amount of basic knowledge is required for successful work Especially note the following 1 Dirt Before removal and disassembly clean the engine Any dirt entering the engine carburetor or other parts will work as an abrasive and shorten the life of engine For the same reason before installing a new part clean off any dust or metal filings 2 Battery Gro
118. ts OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTo prevent damage to electrical parts do not disconnect the battery leads or any other electrical connections when the engine switch is on or while the engine is running OBecause of the large amount of current never keep the engine switch turned to the start position when the starter motor will not turn over or the current may burn out the starter motor windings OTake care not to short the leads that the directly connected to the battery positive terminal to the chassis ground OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was brought on by some other item or items they too must be repaired or replaced or the replacement part will soon fail again OMake sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc Poor wires and bad connections will affect electrical system op eration OMeasure coil and winding resistance when the part is cold at room temperature OElectrical Connectors Female Connectors A Male Connectors B GPO6010181 C 6P06010251 C 8 8 ELECTRICAL SYSTEM Charging System Flywheel Stator Coil Removal e Remove Radiator see Radiator Removal in the Cooling Syst
119. turning it clockwise NOTE OPour in the coolant slowly so that it can expel the air from the engine and radiator OTo install the radiator cap push down it and then turn the cap clockwise to the rest of the way CAUTION Soft or distilled water must be used with the an tifreeze in the cooling system If hard water is used in the system it causes scales accumulation in the water passages and consider ably reduces the efficiency of the cooling system NOTE OChoose a suitable mixture ratio by referring to the coolant manufacturer s instructions Original Coolant Permanent type antifreeze for Type aluminum engine and radiator Color Green Mixed ratio 50 solution of ethylene glycol Freezing Point 35 C 31 F Total amount 2 7 L 2 9 US qt Engine Top End Cylinder Head Cleaning e Scrape the carbon deposits from the head and exhaust port with a suitable tool A OTo avoid gouging use scrapers that are made of a mate rial that will not cause damage e Clean the head in a bath of high flash point solvent and dry it with compressed air A WARNING Clean the cylinder head in a well ventilated area and take care that there are no sparks or flame any where near the working area this includes any ap pliance with a pilot light Do not use gasoline or a low flash point solvent to clean the cylinder head A fire or explosion could result 2 12 PERIODIC MAINTENANCE Per
120. ug and check spark by cranking engine while having the plug touched against engine block Keep the plug as far possible from the plug hole To avoid an electric shock do not hold the plug itself Make sure to hold the plug cap away as NEG ip WEAK gt STRONG Faulty plug insulation Fouled electrodes Faulty ignition coil lncorrect air gap H Replace Clean Replace Correct Y Is unusual smoke emitted out of YES gt Overrich fuel in pilot system H Turn in pilot screw by muffler a minor extent NO Directly and gradually open YES gt OPlugged in carburetor interior H Disassemble and throttle valve by hand Does the clean revolution drop or does engine NO stall at a certain position Is air sucked through carburetor YES gt Loose flange nuts Retighten or inlet manifold flanges Damaged gasket Replace NO Are valve clearances of normal NO gt Compression leakage Adjust valve clearance values Wrong valve timing H Correct alignment of YES timing gear marks Is alignment of timing gear marks NO gt OLargely deviated valve timing Correct alignment of correct timing gear marks Engine Troubleshooting Guide TROUBLESHOOTING 9 5 Fuel consumption is excessive Is compression sufficient Oil co
121. uld show different readings If a megger or a meter with a large capacity battery is used the ignition coil will be damaged e Measure the secondary winding resistance as follows OSet the hand tester to the R x 1 kQ range OConnect the tester between the iron core A and plug cap terminal C Ignition Coil Secondary Winding Resistance x If the tester dose not read as specified replace the coil 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 Electric Starter System ELECTRICAL SYSTEM 8 15 Starter Motor Removal e Disconnect the wire e Remove the mounting bolts B and pull the starter motor A from the engine with the switch lead attached Starter Motor Installation e Clean the starter motor and engine mounting flanges to ensure good electrical contact and tighten the mounting bolts Torque Starter Motor Mounting Bolts 15 N m 1 5 kgf m 11 ft lb Starter Solenoid and Circuit Test NOTE OBefore this test be sure the battery is fully charged e Disconnect the starter motor lead A from the solenoid terminal as shown and keep the lead away from the sole noid terminal e Measure the continuity of the solenoid when activated OSet the hand tester selector switch to the R x 1 Q position and connect the lea
122. und Remove the ground lead from the battery before performing any disassembly operations on the equipment This prevents a the possibility of accidentally turning the engine over while partially disassembled b sparks at electrical connections which will occur when they are disconnected c damage to electrical parts 3 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 Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench 5 Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removal of screws held by a locking agent in order to avoid dam
123. ut the coned disc spring washer A in the direction as shown and tighten the flywheel bolt B Flywheel C Crankshaft D Torque Flywheel Bolt 56 N m 5 7 kgf m 41 ft lb Charging System Operational Inspection e Check battery condition NOTE OAlways check battery condition before condemning other parts of the charging system The battery must be fully charged in order to conduct accurate charging system tests e Warm up the engine to bring the components up to their normal operating temperatures e Measure regulated output voltage at various engine speeds OConnect a voltmeter across the battery terminals The readings should show nearly battery voltage when the engine speed is low and as the engine speed rises the readings should also rise But they must stay within the specified range x If the output voltage is much higher than the specification the regulator is defective or the regulator leads are loose or open lt the output voltage dose not rise as the engine speed increase the regulator is defective orthe alternator output is insufficient for the loads Regulated Output Voltage Battery Voltage to 15 VDC Stator Coil Resistance e Disconnect the stator coil connector e Measure the stator coil resistance OComnect an ohmmeter between stator pins C Stator Coil Resistance 0 20 x If the meter does not read as specified replace the alter nator stator x lf the coil has normal resistance but th
124. xhaust 1 1 1 6 mm 0 043 0 063 in KE05003BS1 Valve Seat Repair e Follow the manufacturer s instructions for use of valve seat cutters special tools Special Tools Valve Seat Cutter Holder 67 57001 1126 Valve Seat Cutter Holder Bar 57001 1128 Inlet Valve Valve Seat Cutter 45 35 57001 1116 Valve Seat Cutter 32 33 57001 1199 Exhaust Valve Valve Seat Cutter 45 30 57001 1187 Valve Seat Cutter 32 630 57001 1120 Xx If the manufacturer s instructions are not available use the following procedure 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Seat Cutter Operating Cares 1 This valve seat cutter is designed only for valve seat repair Therefore the cutter must not be used for other purposes 2 Do not drop or hit the valve seat cutter or the diamond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE ODo not use a wire brush to remove the metal particles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder A in position op erate the cutter B with one hand C Do not apply too much force to the diamond portion NOTE OPrior to grinding apply oil to the cutter and during the operation wash off any ground particles sticking to the cutter with washing oil
125. y type Governor All speed mechanical fly weights Lubrication system Pressure feed by positive displacement pump Oil filter Cartridge type full flow filter Oil pressure switch ON OFF switch When oil filter is removed Oil capacity 2 0 L 2 1 US qt Cooling system Pressurized forced circulation type 2 rows with louverless corrugated fin aluminum Dimensions Hx WL 45 kg 991 Specifications subject to change without notice FD680V FD731V PERIODIC MAINTENANCE 2 1 Periodic Table Periodic Maintenance Chart Torque and Locking Agent Specifications cccccoonocncccncnnnnnocccnonanencnnos Special Tools and Gealant Periodic Maintenance Procedures Fuel Gvstem enee reerrnenrree reenen High Idle Speed Adjustment Low Idle Speed Adjustment 0000000010 Fuel System Cleanliness Inspection Element Cleaning and Inspection Housing Case and Body Inspection Cooling System Coolant Ge EE Engine Top n EE Cylinder Head Cleaning ooooooocccccccccnncnn Valve Clearance Inspection sseeeeeee Valve Clearance Adiustment Valve Seat Inspection ceeeeees Valve Seat Repair Lubrication System ceceeeeeeeeeeceeee Oil Level Inspechon ONG ANI engt ergeet ees Oil Filter Replacement sssnesneeeeeeseeenenn Electrical

印刷プレビュー - Kawasaki

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