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1. Compression Gauge Adapter M14 x 1 25 57001 1159 ST5711598T Piston Ring Compressor Belt 680 991 57001 1320 ST571820ST Cylinder Head ENGINE TOP END 5 7 Compression Measurement e Before measuring compression check 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 sealing the compression 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 44 WARNING To avoid fire do not ground the spark plugs in prox imity to the plug holes Keep the plugs as far away as possible from the plug holes e Open the throttle fully Run the engine by turning the en gine switch key several times until the compression gauge stops rising Read the highest compression value Cylinder Compression MIN 555 kPa 80 psi Engine Oil Temperature 50 60 C 122 140 F Cranking Speed 500 rpm 5 Seconds e Repeat the measurement on the other cylinder x If the compression is higher than the specified value the piston rings cylinder and valves are probably in good con dition x If the compression is
2. Charging System Flywheel and Stator Coil R ectrical System Table of Contents MOV iii A see Flywheel and Stator Coil Installation Charging System Operational Inspection su Stator Coil Resistance Unregulated Stator Output Regulator Removal Regulator Installation Regulator Resistance Ignition System Ignition Coil Removal Ignition Coil Installation Ignition Coil Inspection Spark Plug Cleaning and Inspection ssseesseeeeeeererrrrrrrrrrrrrrrrrrrrrrrrrrrrrrtrrrrrrrrrrrrrrrrrent Spark Plug Gap Inspection 9 2 9 5 9 6 9 7 9 8 9 8 9 9 9 10 9 11 9 11 9 11 9 11 9 12 9 13 9 14 9 14 9 14 9 15 9 15 9 2 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 9 3 Exploded View Torque No Fastener N m kgf m ft Ib 1 Ignition Coil Bolts 6 9 0 70 61 in lb 3 4 2 3 Flywheel Bolt 56 5 7 41 4 Regulator Screws 3 5 0 36 31 in lb 5 Spark Plugs 22 2 2 16 2 G Apply grease Three Bond tb2585G or equivalent 035 om 9 4 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Charging System Regulated Output Voltage 14 1 V DC 15 V DC Stator Coil Resistance 0 01 0 10 Unregulated Stator Output 28 4 V AC 3 000 rpm 26 V AC 3 000 rpm Regulator Resistance in the text Ignition System Ignition Coil Air Gap Pr
3. A se NS KLO2000BW5 Exploded View STARTER SYSTEM 8 3 Remarks 1 Starter Motor Mounting Bolts 2 00 14 4 G Apply grease R Replacement Parts 8 4 STARTER SYSTEM Specifications Item Standard Service Limit Electric Starter System Starter Motor Carbon Brush Length with spring boss 7 125 mm 0 2805 in 4 0 mm 0 16 in Commutator Groove Depth approx 0 8 mm 0 03 in 0 4 mm 0 016 in Commutator Diameter 29 5 mm 1 16 in 29 0 mm 1 14 in Commutator Runout 0 4 mm 0 016 in STARTER SYSTEM 8 5 Special Tool Needle Adapter Set 57001 1457 Es ST5714578T C 8 6 STARTER SYSTEM Electric Starter System Starter Motor Removal e Disconnect the wire e Remove the mounting bolts A and pull the starter motor B 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 19 6 N m 2 00 kgf m 14 4 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 teste
4. NOTE OUse the above procedure to insure proper coil air gap Ignition Coil Inspection e Remove the ignition coils see Ignition Coil Removal e Measure the winding resistance as follows OSet the hand tester to the R x 1 kQ range Special Tool Hand Tester 57001 1394 OMeasure the ignition coil winding resistance as shown in the table Ignition Coil Winding Resistance A C A 11 21 kQ B 14 240 19 29 kO C 11 21 KQ CAUTION Use only Tester 57001 1394 with new battery at room temperature for this test A tester other than the Kawasaki Hand Tester should show different readings If a megger or a meter with a large capacity battery is used the ignition coil will be damaged x lf the tester does not read as specified replace the coil with a new one Ignition System ELECTRICAL SYSTEM 9 15 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 TROUBLESHOOTING 10 1 Troubleshooting Table of Contents Engine Troubleshooting Guide cc ica 10 2 Starter Motor Troubleshooting Guide degt Eet Eet gedd EE 10 6 10 2 TROUBLESHOOTING Engine Troubleshooting Guide If the engine malfunctions check if the way the engine is used is correct If the engine malfunc tions even if th
5. Valve Stem Diameter Service Limit Inlet 5 94 mm 0 234 in Exhaust 6 93 mm 0 273 in 7 KE05007B51 E 6E03010751 KE05008BS51 5 14 ENGINE TOP END Valves Valve Guide Inside Diameter e Use a small bore gauge or a micrometer to measure the inside diameter A of the valve guide B at three positions down the guide length x If the measured valve diameter is greater than the service limit replace the cylinder head with a new one Valve Guide Inside Diameter Service Limit Inlet 6 08 mm 0 239 in Exhaust 7 08 mm 0 279 in Valve Spring Inspection e Inspect the valve spring for pitting cracks rusting and burns Replace the spring with a new one if necessary e Measure the free length A of the spring x lf the measured free length is less than the service limit replace the spring with a new one Valve Spring Free Length Service Limit Inlet 31 1 mm 1 22 in Exhaust 34 5 mm 1 36 in 6F06060351 ENGINE TOP END 5 15 Cylinder Piston Piston Removal e Split the crankcase see Crankcase Cover Removal in the Camshaft Crankshaft chapter e Remove the camshaft see Camshaft Tappet Removal in the Camshaft Crankshaft chapter e Turn the crankshaft to expose the connecting rod cap bolts A e Remove the bolts and take off the connecting rod caps B NOTE ORecord the positions of the connecting rod caps for re
6. MAA oan Kawasaki FX1000V e D gt AMN SY NS Tse Ns Y LIT J Re S 4 Stroke Air 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 Starter System Electrical System Troubleshooting FX921V FX1000V Kawasaki 4 Stroke Air Cooled V Twin Gasoline Engine Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance 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
7. Starter Motor Test NOTE OAlways inspect the Starter 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 A E 3 i 8 8 STARTER SYSTEM Electric Starter System Starter Motor Disassembly e Loosen the terminal nut A e Remove the lead B 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 and end cover bolts B e Remove the end cover C e Move the yoke D with the armature e Pull the rubber insert E from the pinion gear cover and remove the pinion gear fork F e Slide the lead grommet A to outside e Pull the yoke assembly B toward the pinion clutch e Remove Brush Assembly A e Push the stopper B downward and remove the snap ring C e Pull the rear stopper and pinion clutch D from the arma ture shaft START
8. of the transistor causes an interruption in current flow which allows its associated flux collapse and several hundred volts is induced through the primary winding L1 inducing a very large voltage in the secondary winding L2 When the secondary voltage reaches several thousand volts the spark plug SP gap is ionized and ignition occurs The placement of the trigger sensor internal to the ignition insures constant timing over speed and temperature and prevents counterclockwise operation The diode D1 in the ignition shut off circuit blocks inadvertent application of battery voltage pro tecting the internal components of the ignition With the stop switch SW in the closed position primary voltage is routed to ground preventing ignition operation 9 14 ELECTRICAL SYSTEM Ignition System Ignition Coil Removal e Remove Fan Housing see Flywheel and Stator Coil Removal Spark Plug Cap A Stop Switch Lead Connector B Bolts C Ignition Coil D Ignition Coil Installation e Install the ignition coil on the crankcase so that the stop switch lead connector A face the upward and tighten the bolt B first then tighten the another bolt C While tightening bolts adjust the air gap D between the three legs of ignition coil and the two pole plates of magnet to the specified gap value as shown Ignition Coil Air Gap Standard 0 2 0 4 mm 0 008 0 016 in Torque Ignition Coil Bolts 6 9 N m 0 70 kgf m 61 in Ib
9. 0 60 kgf m 52 in Ib e Fix the wire lead and the harness to the inlet manifold A with bands B OPosition the wire lead and or harness on top of the mani fold as shown C Approx 38 mm 1 5 in D Approx 85 mm 3 3 in e Cut excess the band off e Install the removed parts see appropriate chapters Inlet Manifold Inspection e Inspect the intake manifold for cracks or porous casting e Cracks not visible to the eye may be detected by using a metal crack detection system Visual color check com monly found at automotive parts store x lf a crack is present in the intake manifold replace it e Inspect the gasket surfaces for burns and nicks Kc10015BS1 o FUEL SYSTEM 3 19 Fuel Pump Fuel Filter The fuel pump cannot be disassembled If any damage of the pump is noticed replace it with a new one Fuel Pump Removal e Remove Fuel Tubes A Breather Tube B Bolts C Fuel Pump D Fuel Pump Installation e Connect the fuel tubes A and breather tube B fully e Tighten Torque Fuel Pump Mounting Bolts C 5 9 Nm 0 60 kgf m 52 in Ib Fuel Pump Inspection e Check the filter A for plugging or clogging x If the vent hole and the filter are plugged or clogged re move the foreign material from them Fuel Flow Test 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 ventilat
10. on the pinion gear fork B e Tighten the sdenoid mounting bolts Starter Motor Brush Inspection e Measure the overall length A of each brush x lf the brushes are shorter than the service limit replace the brush assembly Brush Length Standard 7 125 mm 0 2805 in Service Limit 4 0 mm 0 16 in Electric Starter System STARTER SYSTEM 8 11 Brush Spring Inspection e Inspection the brush springs for pitting cracks rusting and burrs Replace the brush assembly if necessary e Inspect the springs for weakened conditions and distor tion Replace the brush assembly if necessary x If the brush springs are able to press the brushes firmly into place they may be considered serviceable If they cannot replace the brush assembly 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 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 approx Standard 0 8 mm 0 03 in Service Limit 0 4 mm 0 016 in Bad A Segment B Good C 0 4 mm 0 016 in limit D Mica E e Measure the commutator B outside diamet
11. A between the inner and outer rotor with a feeler gauge Measure the clearance between the highest point of the inner rotor and the highest point of the outer rotor x If the measured valve exceeds the service limit replace the rotors as a set with new ones Inner and Outer Rotor Clearance Service Limit 0 2 mm 0 008 in e Measure the outside diameter A of the outer rotor with a micrometer at several points x If the rotor diameter is less than the service limit replace both the inner and outer rotor with new ones Outer Rotor Outside Diameter Service Limit 40 47 mm 1 593 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 with new ones Outer Rotor Thickness Service Limit 14 94 mm 0 5882 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 with a new one Pump Housing Inside Diameter Service Limit 40 801 mm 1 6063 in e Measure the depth B of the pump housing with a depth micrometer at several points If any of measurement is more than the service limit re place the crankcase cover with a new one Pump Housing Depth Service Limit 15 16 mm 0 5968 in Oil Pump Relief Valve LUBRICATION SYSTEM 6 11 e Meas
12. Free Length 20 6 mm 0 811 in 11 068 mm 0 43575 in 6 6 LUBRICATION SYSTEM Special Tools Oil Pressure Gauge 10 kgf cm 57001 164 ST5701648T Oil Pressure Gauge Adapter PT 1 8 57001 1033 ST5710338T LUBRICATION SYSTEM 6 7 Engine Oil Oil Filter and Oil Cooler CAUTION Engine operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure and accident Engine Oil Level Inspection e Refer to the Engine Oil Level Inspection in the Periodic Maintenance chapter Engine 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 Oil Cooler Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove the oil hose clamps A and take off the oil hoses B from the oil cooler C e Remove the oil cooler bolts D and oil cooler Oil Cooler Installation e Install the oil cooler Torque Oil Cooler Bolts 5 9 N m 0 60 kgf m 52 in Ib e Connect the oil hoses with the clamps Oil Cooler Fin Cleaning e Refer to the Oil Cooler Fin Cleaning in the Periodic Main tenance chapter 6 8 LUBRICATION SYSTEM Pressur
13. and the lowest dial readings is the amount of runout x If the runout exceeds the service limit replace the rod with a new one Rocker Arm Push Rod Runout Service Limit 0 2 mm 0 008 in Valve Mechanism Removal Installation e Remove Rocker Shaft and Rocker Arm see Cylinder Head As sembly Removal Cylinder Head see Cylinder Head Assembly Removal NOTE OWhen removing the valve mechanism parts record their position to reinstall in their original position during as sembly KE04032BS2 C KE04033BS1 C ENGINE TOP END 5 11 Cylinder Head 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 the valve D e Remove the stem seals A NOTE ORemove the stem seals only if the replacement of the stem seals is necessary OValve guide B is not replaceable do not remove it e Install the valves OApply engine oil to the valve stems to avoid damaging the stem seals OCheck to see that the valve moves up and down smoothly in the guide OCheck the valve seating surface between the valve A and the valve seat B 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 me
14. changes to products manufactured previously All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts 2006 Kawasaki Heavy Industries Ltd First Edition 2 May 31 2007 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 EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emission 1 and exhaust emission 2 control systems EM in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board 1 Crankcase Emission Control System A sealed type crankcase emission control system is used to eliminate blow by gases The blow by gases are led to the breather chamber thr
15. cleaner Fuel Fuel Requirement Fuel Pump Type Governor Type Heavy duty type Primary element Secondary element Unleaded regular grade gasoline Pulse diaphragm pump Flyweight all speed governor 1 Idle speeds may vary depending on each equipment Refer to the equipment specification FUEL SYSTEM 3 5 Governor Link Mechanism Control Panel Assembly Removal e Remove Air Cleaner see Air Cleaner Body and Bracket Removal Clamp A Breather Hose B Inlet Pipe Mounting Bolts C and Nuts D Ground Lead E Inlet Pipe F e Remove the control panel assembly A while unhooking the governor spring B end loop at the panel bracket Control Panel Assembly Installation e Before installing the control panel assembly check to see that the engine speed control lever A move smoothly in all directions x If any part is worn or damaged replace the control panel assembly with a new one e Replace the gaskets A with new ones e Install Gaskets Control Panel Assembly B Inlet Pipe C Ground Lead D e Tighten Torque Carburetor and Inlet Pipe Mounting Bolts E 5 9 A N m 0 60 kgf m 52 in Ib Carburetor and Inlet Pipe Mounting Nuts F 5 9 N m 0 60 kgf m 52 in Ib 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 KC04041BS1 C 3 6 FUEL
16. e Install the removed parts see appropriate chapters Breather Valve Inspection e Inspect the reed valve A for breakage crack or distor tion replace it with a new one if necessary e Inspect the plate B for damage or rough contact surface replace it with a new one if necessary e Inspect the valve seating surface C The surface should be no nicks or burrs NOTE OThe mounting screw is a self tapping one Be aware that misthreading or overtightening screw will strip the female threads and break the hole CAMSHAFT CRANKSHAFT 7 13 Breather Breather Pipe Removal e Remove Camshaft see Camshaft Tappet Removal Bolts A Breather Pipe Cover B e Remove Upper Breather Pipe A e Remove Lower Breather Pipe A Breather Pipe Installation e Install the lower and upper breather pipes so that fit the projection A and notch B e Install Breather Pipe Cover e Tighten Torque Breather Pipe Cover Bolts 5 9 N m 0 60 kgf m 52 in Ib 7 14 CAMSHAFT CRANKSHAFT Camshaft Tappet Camshaft Tappet Removal e Set the engine on a clean surface while parts are re moved e Drain the oil see Engine Oil Change in the Periodic Main tenance chapter e Remove Crankcase Cover see Crankcase Cover Removal Rocker Covers see Cylinder Head Assembly Removal in the Engine Top End chapter Push Rods see Push Rod Removal in the Engine Top End chapter e Turn the crankcase upside do
17. faster as the throttle is opened The pilot screw controls the amount of fuel air mixture allowed through the pilot outlet but does not meter the bypass holes A moderate amount of air comes in around the throttle valve at an idle so adjusting the pilot screw changes the fuel air ratio Turning the pilot screw Idle mixture screw out Counterclockwise enrichens the mixture turning it in clockwise leans the mixture lt AIR ZA MIXTURE KCO5151BW3 C 3 10 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 jets B simultaneously when the switch key turned to the OFF position The valve opens automatically when the switch key is turned to the Run position Low Idle 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 adjusting the idle speed NOTE O The main jet high altitude kits are available
18. installing 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 arrow match mark A on the piston head in relation to K Mark B on the connect ing rod No 1 cylinder K Mark on the connecting rod is face to face with No 2 cylinder K Mark on the connecting rod Keep parts together as a set e Remove the piston pin snap ring A with needle nose pliers B e Remove the piston by pushing the piston pin A to the direction from which the snap ring was removed KE P 5 16 ENGINE TOP END Cylinder Piston e Remove the top and second rings with piston ring pliers Special Tool Piston Ring Pliers 57001 115 e If the special tool is not available carefully spread the ring opening with your thumbs then push up to the opposite side of the ring A to remove it e Remove the 3 piece oil ring with your thumbs in the same manner Piston Installation e Install the expander A in the piston oil ring groove so that the expander ends B touch together never overlap them e Install the upper and lower steel rails There is no UP or Down to the rails They can be installed either way e Do not mix up the top and second rings e With the marked side facing up install the second ring A and top ring B in that order e The rings should turn freely in the grooves e Align the piston and rings wit
19. leecslealtitgadedideiassneadseciiteatuaasen 6 12 Cleaning ANA INSpEction EE 6 12 6 2 LUBRICATION SYSTEM Exploded View KF02014BW5 LUBRICATION SYSTEM 6 3 Exploded View Fastener f Remarks 1 Oil Filter Joint Pipe 6 9 0 70 61 in lb 2 Oil Pump Cover Plate Bolts 5 9 0 60 52 in lb 3 Oil Filter 11 8 1 2 104 in lb R 4 Engine Oil Drain Plugs 6 9 0 70 61 in lb EO 5 Oil Filler Mounting Bolt 5 9 0 60 52 mb 6 Oil Cooler Bolts 5 9 0 60 52 in lb EO Apply engine oil R Replacement Parts 6 4 LUBRICATION SYSTEM Engine Oil Flow Chart kf04009b 6 LUBRICATION SYSTEM 6 5 Specifications Standard Engine Oil Grade SF SG SH SJ or SL class Viscosity SAE40 SAE30 SAE10W 30 SAE10W 40 or SAESW 20 Capacity When the oil filter is not 1 7 L 1 8 US at removed When the oil filter is removed 1 9 L 2 0 US qt Level Operating range grid area on dipstick Oil Pressure 294 to 490 kPa 43 to 71 psi Engine oil temperature 50 C to 60 C 122 144 F a gt AO Oil Pump Inner and Outer Rotor Clearance 0 2 mm 0 008 in Outer Rotor Outside Diameter 40 47 mm 1 593 in Outer Rotor Thickness 14 94 mm 0 5882 in Pump Housing Inside Diameter 40 801 mm 1 6063 in Pump Housing Depth 15 16 mm 0 5968 in Pump Shaft Outside Diameter 10 923 mm 0 43004 in Pump Shaft Bearing Inside Diameter Relief Valve Spring
20. mixture flows out the end of the main nozzle into the carburetor bore where it is atomized by the high speed air flow and carried into the engine OSA aL ae a 3 e co H KCO5150BW3 C FUEL SYSTEM 3 9 Carburetor The pilot system includes the pilot jet F pilot screw G Idle mixture screw pilot air jet H pilot outlet I and the bypass holes J The pilot system meters the fuel air mixture while the engine is idling and running under a light load Under these conditions there is very little air flow through the carburetor bore so little that it is not enough to draw fuel through the main system of the carburetor and atomize it Instead the fuel is drawn through the pilot system since the nearly closed throttle valve K causes high speed air flow past the pilot outlet and bypass holes even at low engine speed Fuel flow in the pilot system is metered by the pilot jet Air for better atomization is admitted via the pilot air jet in the mouth of the carburetor The fuel air mixture passes into the bore of the carburetor side stream of the throttle valve through the bypass holes and pilot outlet While the throttle valve is almost closed it covers the small bypass holes opening into the bore from the pilot system As the throttle valve begins to open it uncovers the bypass holes allowing more fuel air mixture to flow The extra flow is needed because the engine starts to run
21. necessary e Check the top of the cam lobes B for wear burrs or un even contact Replace the camshaft with a new one if necessary Camshaft Bearing Journal Wear e Measure the height A of each cam lobe x lf the cam height is less than the service limit for either lobe replace the camshaft with a new one Cam Lobe Height O Service Limit Inlet 34 49 mm 1 358 in Exhaust 35 11 mm 1 382 in GE11012281 7 16 CAMSHAFT CRANKSHAFT Camshaft Tappet e Measure PTO side camshaft journal diameter A at sev eral points around the journal circumference x lf the journal diameter is less than the service limit re place the camshaft with a new one PTO Side Camshaft Journal Diameter Service Limit 19 98 mm 0 7866 in e Measure the inside diameter A of the camshaft bearing on the crankcase at several points This bearing is not replaceable Xx lf the inside diameter is more than the service limit re place the crankcase with a new one Camshaft Bearing Inside Diameter Crankcase Service Limit 20 14 mm 0 7929 in CAMSHAFT CRANKSHAFT 7 17 Crankshaft Connecting Rod Connecting Rod Removal e Refer to the Piston Removal in the Engine Top End chap ter Connecting Rod Installation e Refer to the Piston Installation in the Engine Top End chapter Crankshaft Removal e Set the engine on a clean surface while parts are re moved e Drain the oil see Engine Oil C
22. not use compressed air on an assembled carbu retor or the floats 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 to or deterioration of the parts The carburetor body has plastic parts that can not be removed Do not use a strong carburetor cleaning solution which could attack these parts instead use a mild high flash point cleaning solu tion 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 see Carburetor Disassem bly Assembly e Immerse all the metal parts in a carburetor cleaning solu tion e Rinse the parts in water and dry them with compressed air e Do not use rags or paper to dry parts Lint may plug the holes or passages e Blow air through the holes and fuel passages with the compressed air All holes must be open e Assemble the carburetor see Carburetor Disassem bly Assembly 3 16 FUEL SYSTEM Carburetor Carburetor Inspection 44 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 s
23. on the cap 3 22 FUEL SYSTEM Air Cleaner e Turn the cap to the clockwise until the lock mark A Element Cleaning and Inspection Air cleaner elements are not recommended to be cleaned and each air cleaner element should be replaced with new ones e Refer to the Element Cleaning and Inspection in the Pe riodic Maintenance chapter Air Cleaner Body and Bracket Removal e Remove the air cleaner elements if necessary see Ele ment Removal e Loosen the clamp A e Remove Bolt B Upper Bracket C e Take out the air cleaner body D together with the inlet hose E e Remove Nuts A Lower Bracket B Air Cleaner Body and Bracket Installation e Install the air cleaner lower bracket A with the nuts B to the specified torque Torque Air Cleaner Body Bracket Mounting Nuts 19 6 N m 2 00 kgf m 14 4 ft lb Air Cleaner FUEL SYSTEM 3 23 e Set the air cleaner body A onto the lower bracket so that the air inlet duct B is facing upward e Install the inlet hose C and tighten the clamp D e Install the upper bracket E e Tighten Torque Air Cleaner Mounting Bracket Bolt F 19 6 N m 2 00 kgf m 14 4 ft lb Air Cleaner Housing Cap and Body Inspection e Refer to the Air Cleaner Housing Cap and Body Inspec tion in the Periodic Maintenance chapter COOLING SYSTEM 4 1 Cooling System Table of Contents Exploded MiS Wii aaa ales i
24. removed parts 5 10 ENGINE TOP END Cylinder Head Push Rod Removal e Set each piston at the T D C of the compression stroke e Remove the rocker covers and rocker arm see Cylinder Head Assembly Removal e Pull out the push rods A NOTE OMark the push rods to reinstall in their original position during assembly Push Rod Installation e Set each piston at the T D C of the compression stroke e Apply engine oil to the both ends and shaft of the push rod e Install the push rods A in their original positions on each cylinder OTo Install the push rod in a correct position on the tappet B insert the push rod so that the end of the push rod is sliding down C along inside wall D of the crankcase and position the push rod end on to the tappet e Check that both inlet and exhaust push rods on each cylinder are at lowest position on the cam lobes E If the piston is not at the T D C of the compression stroke turn the flywheel clockwise one turn 360 and reset each pis ton at the T D C of the compression stroke e Be sure the end of the push rods are correctly seated on the tappets e Tighten the valve clearance adjusting screws and lock nuts e Check and adjust the valve clearance Push Rod Inspection e Place the push rod on V blocks as far apart as possible and set a dial gauge A on the rod at a halfway point between the blocks Turn the rod to measure the runout The difference between the highest
25. replace the connecting rod with a new one Connecting Rod Big End Width Service Limit 22 070 mm 0 8937 in KG06035BS1 o KGO6O036BS1 o KOSCH P CAMSHAFT CRANKSHAFT 7 19 Crankshaft Connecting Rod e Measure the crankpin width A with a dial caliper x If the crankpin width is greater than the service limit re place the crankshaft with a new one Crankpin Width Service Limit 49 0 mm 1 93 in DA LL U THe A Connecting Rod Big End Bearing Crankpin Wear e Apply a light film of engine oil on the threads of the cap bolts e Install the cap bolts and tighten the bolts to the specified torque see Piston Installation in Engine Top End chap ter e Measure the big end inside diameter A at several points with a telescoping gauge or inside micrometer lf the inside diameter is greater than the service limit re place the connecting rod with a new one Connecting Rod Big End Inside Diameter Service Limit 42 04 mm 1 655 in e Measure the crankpin outside diameter A OUse a micrometer to measure several points around the crankpin circumference x lf the crankpin diameter is less than the service limit re place the crankshaft with a new one Crankpin Outside Diameter Service Limit 41 94 mm 1 651 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
26. terne Piston Ring End Gap Piston Pin Piston Pin Hole and Connecting Rod Wear Piston Diameter Cylinder Inside Diameter 5 2 5 4 5 6 5 7 5 7 5 8 5 9 5 10 5 10 5 10 5 10 5 11 5 11 5 12 5 13 5 13 5 13 5 13 5 13 5 13 5 13 5 13 5 14 5 14 5 15 5 15 5 16 5 18 5 18 5 19 5 20 5 20 5 21 5 21 5 2 ENGINE TOP END Exploded View Exploded View ENGINE TOP END 5 3 Fastener Remarks 1 Cylinder Head Bolts 34 2 Rocker Case Bolts 52 in lb 3 Exhaust Pipe Nuts 16 2 4 Valve Clearance Adjusting Locknuts 87 in lb 5 Connecting Rod Big End Cap Bolts 20 6 2 10 15 2 EO EO Apply engine oil R Replacement Parts S Tighten the fasteners following the specified sequence 5 4 ENGINE TOP END Specifications Item Service Limit Cylinder Head 555 kPa 80 psi Engine Oil Temperature Cylinder Compression MIN 50 60 C 122 144 F Cranking Speed 500 rpm 5 Seconds Cylinder Head Warp 0 05 mm 0 002 in Valves Valve Head Thickness Inlet Exhaust 0 4 mm 0 016 in Valve Stem Runout Inlet Exhaust 0 05 mm 0 002 in Valve Stem Diameter Inlet 5 94 mm 0 234 in Exhaust 6 93 mm 0 273 in Valve Guide Inside Diameter Inlet 6 08 mm 0 239 in Exhaust 7 08 mm 0 279 in Valve Spring Free Length Inlet 31 1 mm 1 22 in Exhaust 34 5 mm 1 36 in Rocker Arm Push Rod Runout Inlet Exhaust 0 2 m
27. too high check the following 1 Carbon build up on the piston crown and cylinder head clean off any carbon on the piston crown and cylinder head 2 Cylinder head gasket use only the proper gasket The use of a gasket of incorrect thickness will change the compression 3 Valve guides and piston rings worn valve guides and or worn piston oil rings may cause rapid carbon accumula tion in the combustion chamber This may be indicated by white exhaust smoke x If the cylinder compression is lower than the MIN check the following 1 Gas leakage around the cylinder head replace the damaged gasket with a new one and check the cylinder head warp Condition of the valve seating Valve clearance Piston cylinder wear piston seizure Piston ring piston ring groove E IS KEDABOS1 P 5 8 ENGINE TOP END Cylinder Head Cylinder Head Assembly Removal e Remove Inlet Manifold see Inlet Manifold Removal in the Fuel System chapter Spark Plug e Unscrew the rocker cover bolts A and remove the cover B and the gasket e When removing the 1 2 cylinder head set each pis ton at the top dead center T D C A of the compression stroke e Push out the rocker shafts A e Remove Rocker Arms B Engine Shroud see Engine Shroud Removal Installa tion in the Cooling System chapter e Loosen the cylinder head bolts 1 4 turn in the sequence as shown CAUTION If the above procedure is not fol
28. washer Charging System ELECTRICAL SYSTEM 9 9 e Using a suitable flywheel puller A remove the flywheel B CAUTION Always use flywheel puller e Remove Woodruff Key A Stator Coil Screw B Stator Coil C Flywheel and Stator Coil Installation e Install the stator coil and tighten the screws Torque Stator Coil Screws 3 4 N m 0 35 kgf m 30 in Ib e Using a cleaning fluid clean off any oil or dirt on the 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 e Install the fan A e Install the plate B so that the slit C fit to the bosses D on the fan e Tighten Torque Cooling Fan Plate Mounting Stud Bolts 5 9 N m 0 60 kgf m 52 in Ib e Put the washer A as shown so that the 0 mark B faces up e Tighten Torque Flywheel Bolt C 56 N m 5 7 kgf m 41 ft Ib KHO7043BS1 C 9 10 ELECTRICAL SYSTEM Charging System e Install the guide A to the fan housing B e Install the fan housing e Tighten Torque Fan Housing Bolts 5 9 N m 0 60 kgf m 52 in Ib e Install the screen and guard e Tighten Torque Cooling Fan Screen Bolts 5 9 N m 0 60 kgf m 52 in 1b Guard Mounting Bolts 5 9 N m 0 60 kgf m 52 in 1b Charging System Operational Inspection e Check
29. 1 cu in Direction of Rotation Oil Filter Oil Capacity when engine is completely dry Counterclockwise facing the PTO shaft Cartridge type full flow filter 2 35 L 2 48 US qt Cooling System Dimensions LxWxH Forced air cooling by fan with oil cooler 511 mm x 502 mm x 626 mm 20 12 in x 19 76 in x 24 65 in Dry Weight without muffler 62 6 kg 138 Ibs Specifications subject to change without notice PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart Belge MEM A sd Ann Re eo iKa nn dut else Mee EE Special Tools Periodic Maintenance Procedures ii iiiiiiieeeeeeeerceecececececececeeeceeeeneeenee SE GE nt toria en ee tanins tn au Low Idle Speed Adjustment Highidi Sb ed AdiiSstme entzss A Re Fuel System Cleanliness Inspection Element Cleaning and Inspection suit dar due la sentent ancien Air Cleaner Housing Cap and Body Inspection Ene Jop End us a oia ia idos Cylinder e ERT Le SEET Valve Clearance Inspection Valve Clearance AdjusiMeME EE Valve Seat Inspection EEEE EEEE Valve Seat Repair te le e EE EE Engine Oil Level Inspection Engine e Uni e GE Oil Filter Replacement Oil Cooler Fin Cleaning Electrical System 00000 Spark Plug Clea
30. 1 in Oil 1 0 mm 0 039 in Piston Pin Piston Pin Hole and Connecting Rod Wear e Remove the piston pin e Measure the diameter of the piston pin diameter with a micrometer at several points x If the outside diameter is less than service limit replace the piston pin with a new one Piston Pin Outside Diameter Service Limit 20 96 mm 0 8252 in e Measure the inside diameter A of the piston pin hole at several points on both side Use a dial bore gauge x lf the inside diameter is greater than the service limit re place the piston with a new one Piston Pin Hole Inside Diameter Service Limit 21 08 mm 0 8299 in e Measure the inside diameter A of the connecting rod small end at several points Use a dial bore gauge xlf the inside diameter is more than the service limit re place the connecting rod with a new one Connecting Rod Small End Inside Diameter Service Limit 21 06 mm 0 8291 in KEO6060BS1 o KEO6090BS1 o Cylinder Piston ENGINE TOP END 5 21 Piston Diameter e Measure the outside diameter A of the piston 7 mm 0 28 in B up from the bottom of the piston at a right angle to the direction of the piston pin hole x If the measured outside diameter is less than the service limit replace the piston with a new one Piston Diameter Service Limit 88 93 mm 3 501 in Cylinder Inside Diameter e Clean and measure the cylinder inside diameter OUse a cylinder
31. 22 Air Cleaner Housing Cap and Body Inspection 3 23 3 2 FUEL SYSTEM Exploded View Exploded View FUEL SYSTEM 3 3 Fastener Remarks 1 Carburetor and Inlet Pipe Mounting Bolts 5 9 0 60 52 in lb 2 Carburetor and Inlet Pipe Mounting Nuts 5 9 0 60 52 in lb 3 Air Creaner Bracket Mounting Nuts 19 6 2 00 14 4 4 Air Creaner Mounting Bracket Bolt 19 6 2 00 14 4 5 Fuel Pump Mounting Bolts 5 9 0 60 52 in lb 6 Inlet Manifold Bolts 5 9 0 60 52 in lb S 7 Governor Shaft Plate Screws 2 0 0 20 18 in lb 8 Governor Arm Joint Bolt 5 9 0 60 52 in lb 9 Governor Arm Clamp Nut 7 8 0 80 69 in lb EO Apply engine oil R Replacement Parts S Tighten the fasteners following the specified sequence 3 4 FUEL SYSTEM Specifications Throttle Bore Diameter Venturi Diameter Main Jet MJ Pilot jet PJ Main air jet MAJ Pilot air jet PAJ Pilot Air Screw Turns out PS Idle Mixture Screw Turns Out Float Level Idle Speed 1 Low Idle Speed Carburetor idle rpm Low Idle Speed Governor idle rpm High Idle Speed Item Standard Carburetor Specifications Make Type FX921V Nikki 621300 021 FX1000V Nikki 621300 011 30 mm 1 2 in 23 mm 0 90 in L 134 R 140 52 p1 4 di L 2 1 4 R 2 3 8 Float parallel to carburetor body 1 450 r min rpm 1 550 r min rpm 3 600 r min rpm Air Cleaner Type Pre cleaner Second stage
32. 4 in G PTO Side KG04063BS1 o e Apply a non permanent locking agent to the oil passage plugs and tighten them Torque Oil Passage Plugs 3 9 N m 0 40 kgf m 34 in Ib Crankcase Inspection e Measure the inside diameter A of the PTO shaft bearing on the crankcase at several points x If inside diameter is greater than the service limit replace the bearing see Crankcase Assembly PTO Shaft Bearing Inside Diameter Service Limit 42 15 mm 1 659 in 7 10 CAMSHAFT CRANKSHAFT Crankcase Crankcase and Crankcase Cover Cleaning e Remove Oil Pump and Relief Valve see Oil Pump Relief Valve Removal in the Lubrication System chapter Camshaft and Tappets see Camshaft Tappet Removal Crankshaft see Crankshaft Removal Breather Pipes and Cover see Breather Pipe Removal e Clean up the crankcase and cover with a high flash point solvent and blow out any foreign particles that may be in the pockets inside of the crankcase with compressed air 44 WARNING Clean the crankcase and cover in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents CAMSHAFT CRANKSHAFT 7 11 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 gasket
33. E 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 x lf the oil level is FULL range C drain the excess oil by loosening the drain plug Engine Oil Change e Change the oil after first 8 hours of operation Thereafter change oil every 100 hours of operation e Start and warm up the engine to drain the oil easily e Stop the engine e Place the engine on a level surface e Place a suitable container under the engine e Remove the oil drain plug A and drain the oil A WARNING Be careful of hot oil when draining It may be hot enough to burn you severely e Replace the O ring B with a new one e Apply engine oil to the thread of the plugs and O rings if necessary e Install the oil drain plugs with the O rings and tighten them Torque Oil Drain Plugs 6 9 N m 0 70 kgf m 61 in Ib KMO8002BS1 C PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures e Remove the oil filler cap and pour in the specified type and the amount of oil lt Ambient Temperature gt Engine Oil 200 100 ot 10 20t Grade SF SG SH SJ or SL Class Viscosity SAE40 SAE30 SAE10W 30 SAE10W 40 or SAE5W 20 Capacity When the oil filter is not removed 1 7 L 1 8 US qt When the oil filter is removed 1 9 L 2 0 U
34. ER SYSTEM 8 9 Electric Starter System Starter Motor Assembly 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 VUm e Inspect the boots A rubber insert B and grommet C for visible damage xlfit is damaged replace it e Install the pinion clutch A e Install the stopper B so that the hollow side face the out side e Install the snap ring C to the groove of the shaft e Slide the stopper until the stopping with the snap ring e Install the collar D so that the smaller diameter face the outside e Apply grease to the pinion gear fork fingers e Assemble the pinion gear fork E as shown e Install the armature assembly A to the pinion gear cover e Install the rubber insert B as shown e Install the yoke so that the slit A fit the projection B of the rubber insert Woon 8 10 STARTER SYSTEM Electric Starter System e Using the suitable tool for instance socket wrench of 22 mm expand the brushes as shown e Install the brush assembly A with the suitable tool in stalled e Pull out the suitable tool e Fit the notch on the lead grommet B and slit on the yoke e Install the washer C e Install the end cover so that the projection A fit the groove B of the grommet e Tighten the through bolts and end cover bolts e Engage the hook on the starter solenoid with the hook A
35. Inspection in the Periodic Maintenance chapter 3 12 FUEL SYSTEM Carburetor Carburetor Removal 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 the control panel assembly see Control Panel Assembly Removal e Close the fuel shut off valve in the equipment e Remove the clamp A e Disconnect Solenoid Valve Connector B Fuel Tube C e Unhook the throttle link spring A at the throttle shaft lever clip end B with a long nose plier e Unhook the throttle link rod C from the throttle shaft lever crip end e Remove the carburetor Carburetor Installation e Clean the mating surface of the carburetor and inlet man ifold e Replace the gaskets A with new ones e Connect the solenoid valve connector e Install the insulator B carburetor C and new gaskets sequence as shown KCO5148BS2 Carburetor FUEL SYSTEM 3 13 e Install the throttle link rod A and spring B to the throttle shaft lever clip C NOTE OTake care not to bend the throttle link rod during instal lation e Make sure that 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 e Install the
36. NCE 2 7 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 Low Idle Speed Adjustment e Disconnect all possible external loads from the engine e Start and warm up the engine thoroughly 44 WARNING Always keep your hands clear of the moving parts e Move the throttle lever at a dash to the idle position e Hold the throttle lever on the carburetor in closed position turn the governor arm clockwise all the way and adjust the low idle speed screw A until the engine idles at spec ified speed Low Idle Speed Carburetor idle rpm 1 450 rpm e Release the throttle lever e Loosen the locknut A e Adjust the low idle speed set screw B on the control plate to obtain the specified governor low idle speed Low Idle Speed Governor idle rpm 1 550 rpm e Tighten the locknut 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 2 8 PERIODIC MAINTENANCE Periodic Maintenance Procedures Always keep your hands clear of the moving parts e Loosen the locknut A and unscrew the high idle set screw B few turns e Move the throttle lever on dash to obtain the specified high
37. R 0 05 mm 0 002 in 41 90 mm 1 650 in Crankcase PTO Shaft Bearing Inside Diameter 42 15 mm 1 659 in CAMSHAFT CRANKSHAFT 7 5 Special Tools and Sealant Oil Seal amp Bearing Remover Kawasaki Bond Liquid Gasket Gray 57001 1058 92104 1063 gt ST5710588T ST921063ST Bearing Driver Set 57001 1129 ST5711298T 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 Engine Oil Change in the Periodic Main tenance chapter e Remove Ignition Coils see Ignition Coil Removal in the Electrical System chapter Flywheel and Stator Coil see Flywheel and Stator Coil Removal in the Electrical System chapter Starter Motor see Starter Motor Removal in the Starter System chapter Carburetor see Carburetor Removal in the Fuel System chapter Governor Arm see Governor Arm Removal in the Fuel System chapter e Unscrew the mounting bolts in the order shown 1 to 11 and remove the crankcase cover A from the crankcase OThere are two knock pins on the crankcase mating surface Using a wooden or plastic mallet gently tap crankcase to loosen the crankcase cover Crankcase Cover Disassembly e Remove Crankcase Cover see Crankcase Cover Removal Governor Shaft see Governor Shaft Removal in the Fuel System chapter e Pry the governor shaft oil seal A with t
38. Removal in the Electrical System chapter Carburetor see Carburetor Removal in the Fuel System chapter Governor Arm see Governor Arm Removal in the Fuel System chapter Rocker Cover see Cylinder Head Assembly Removal Engine Shroud Bolts A Engine Shroud B e Install the engine shroud e Tighten Torque Engine Shroud Bolts 5 9 N m 0 60 kgf m 52 in Ib ENGINE TOP END 5 1 Engine Top End Exploded View Specifications Special Tools Cylinder Head Table of Contents Compression Measurement Cylinder Head Assembly Cylinder Head Assembly Push Rod Removal Push Rod Installation Push Rod Inspection PACA LOUE A INStallaiOn Le Eege te Te nn Valve Mechanism Removall Installation ooooccocccnccnnccnncnnnconcconcnonononcnnnnconanoncnonanono Cylinder Head Cleaning Cylinder Head Inspection Gants hr rt laica Rocker Arm Inspection Valve Clearance Inspecti CO A SER PTEE E EIE TEE Valve Clearance TEE Valve Seat Inspection Valve Seat Repair Valve Head Thickness Valve Stem Runout Valve Stem Diameter Valve Guide Inside Diameter Valve Spring Inspection Cylinder Piston Piston Removal Piston Installation Piston Cylinder Seizure Piston Cleaning Piston Ring and Ring Groove WAM sn sun Men nan
39. S qt e Check the O ring A on the oil filler cap for damage Re place the oil filler cap with a new one if O ring is damaged When checking the oil level do not turn oil filler cap on threads NOTE OSome 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 more frequently than recom mended interval KFO5004BS1 Oil Filter Replacement e Drain the engine oil see Engine Oil Change e Remove the oil filter A with the oil filter wrench B or strap wrench Special Tool Oil Filter Wrench 57001 1249 OWhen unscrewing the oil filter place a suitable container beneath the oil drip tray to receive oil from the oil filter and oil passages in the engine e Replace the oil filter A with a new one e Apply light film of engine oil to the seal B e Install the oil filter Torque Oil Filler 11 8 N m 1 20 kgf m 104 in Ib OTurn the filter until the seal contacts mounting surface C of the engine Then turn the filter BY HAND S 2 3 to 3 4 turn e Run the engine at slow idle speed for 3 minutes OWhile running the engine check for oil leaks around it e Stop the engine and check the oil level see Engine Oil Level Inspection 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Oil Cooler Fin Cleaning e Clean dirt off the outside fins A with brush or with com pressed air HOP P Ele
40. SYSTEM Governor Link Mechanism Governor Arm Removal e Remove Control Panel Assembly see Control Panel Assembly Removal Solenoid Valve Connector A e Loosen the clamp nut B and take off the governor arm C e Unhook the throttle link rod spring D end loop and clear the throttle link rod lower end E Governor Arm Installation e Install the inside governor arm A onto the governor shaft B e Install the outside governor arm C onto the inside gov ernor arm temporarily e Be sure the link spring D around the throttle link rod E is in place and that it pulls the governor arm and throttle lever F each other e Turn the top end of the governor arm clockwise to fully open the carburetor G throttle valve and hold it there e Turn the governor shaft clockwise fully to the end of its travel e Tighten the clamp nut Torque Governor Arm Clamp Nut 7 8 N m 0 80 kgf m 69 in 1b e Install the control panel assembly and connect the gov ernor arm with the governor spring H Governor Assembly Removal e Remove Camshaft see Camshaft Tappet Removal in the Camshaft Crankshaft chapter Washer A Snap Ring B Sleeve C Governor Plate D Snap Ring E Steel Balls F Ball Guide G Ball Plate H KC04042BS2 C KC04043BS1 C FUEL SYSTEM 3 7 Governor Link Mechanism Governor Assembly Installation e Fit the snap ring A into the groove securely e Turn the governor plate by hand an
41. aced Lap the valves to the seats after refacing e Coat the valve seat with machinist s dye e Push the valve into the guide e Rotate the valve against the seat with a lapping tool e Pull the valve out and check the seating pattern on the valve head It must be the correct width A and even all the way around 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 Exhaust 1 0 1 5 mm 0 039 0 059 in Inlet 0 7 1 1 mm 0 028 0 043 in KEG5003BS1 Valve Seat Repair e Follow the manufacture s instructions for use of valve seat cutters Special Tools Inlet Valve Valve Seat Cutter 45 27 5 57001 1114 Valve Seat Cutter 32 p30 57001 1120 Valve Seat Cutter Holder p6 57001 1360 Exhaust Valve Valve Seat Cutter 45 35 57001 1116 Valve Seat Cutter 32 635 57001 1121 Valve Seat Cutter Holder oT 57001 1126 Valve Seat Cutter Holder Bar 57001 1128 2 12 PERIODIC MAINTENANCE Periodic Maintenance Procedures If the manufacture s instructions are not available use the following procedure Seat Cutter Operating Cares 1 This valve seat cutter is designed only for valve seat re pair Do not use the valve seat cutter for other purpose 2 Do not drop or hit the valve s
42. against both bearing journals OTurn the crankshaft slowly to measure the runout The difference between the highest and the lowest dial gauge readings TIR is the amount of runout x If the measurement exceeds the service limit replace the crankshaft with a new one Crankshaft Runout Service Limit TIR 0 05 mm 0 002 in KG06037BS1 o 7 20 CAMSHAFT CRANKSHAFT Crankshaft Connecting Rod Crankshaft Journal Wear e Measure PTO side crankshaft journal 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 41 90 mm 1 650 in STARTER SYSTEM 8 1 Starter System Table of Contents EXPlOded WE 8 2 eene de EE 8 4 Special Tola ld paa 8 5 Electric Starter Sy iMac 8 6 Starter Motor Removal inocuidad rd cir EEN dean 8 6 Starter Motor Installaton see 8 6 Starter Solenoid and Circuit Test 8 6 Starter MOOSE EE EA EAE A AAE 8 7 Starter Motor DiSas SO MbDlY visionar li gege large nt ee 8 8 Starter Motor Assembly E 8 9 Starter Motor Brush Inspection 8 10 Brush Spring Inspection ssssssrsrerttertrtntttrr ttnn rtnn AEEA EEEE EAEEEEEEEAEEEEEEEEEEEEEEEEEEEEEE EEEE EEEE EEEE 8 11 Armature Ee 8 11 YOKE Assembly Inspection EE 8 12 Pinion Clutch Inspection ss 8 13 8 2 STARTER SYSTEM Exploded View Ke w LAG
43. 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 Special Tool Needle Adapter Set B 57001 1457 If the resistance is less than infinite the positive brush is shorted to ground Replace the yoke assembly Positive Brush to Ground Resistance dell 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 If the meter dose not read close 0 Q the yoke assembly is faulty Replace it Negative Brush to Ground Resistance Close 0 Q lt Pz a y AY E Y es ZS e KS e A7 bb KHO9015B S STARTER SYSTEM 8 13 Electric Starter System Pinion Clutch Inspection e Remove the pinion clutch e Turn the pinion gear A by hand The pinion gear should turn counterclockwise freely but should not turn clock wise lf the pinion clutch dose not operate as it should or if it makes noise replace the pinion clutch KL 076048 P ELECTRICAL SYSTEM 9 1 El Exploded VieW Specifications Special Tool Wiring Dagram cee Precautions
44. asure warp by inserting a thickness gauge B between the straightedge and head x 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 05 mm 0 002 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 If a 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 5 12 ENGINE TOP END Cylinder Head Rocker Arm Inspection e Measure the diameter A of the rocker shafts with a mi crometer at several points of bearing the rocker arm lf the outside diameter is less than the service limit re place the rocker shaft Rocker Shafts Outside Diameter Service Limit Inlet Exhaust 11 95 mm 0 4705 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 B of the rocker arm at sev eral points using a dial bore gauge or inside micrometer Xx If the inside diameter is more than the service limit re place the rocker ar
45. ay burn out the starter motor windings OTake care not to short the leads that are directly con nected to the battery positive terminal to the chassis ground OTroubles may involve one or all items in some cases Never replace a defective part without determining what CAUSED the failure If the failure was occurred by an other item or some other items repair and or replace the item s Or the failure may happen again OMake sure all connectors in the circuit are clean and tight and examine the leads for signs of burning fraying etc Poor leads and bad connections will affect electrical sys tem operation OMeasure the coil and the winding resistance when the parts are cold at room temperature OElectrical connectors Connectors A Connectors B GPO7000281 6P07000351 C 9 8 ELECTRICAL SYSTEM Charging System Flywheel and Stator Coil Removal e Remove Air Cleaner see Air Cleaner Body and Bracket Removal in the Fuel System chapter Oil Cooler see Oil Cooler Removal in the Lubrication System chapter Regulator see Regulator Removal Fuel Pump see Fuel Pump Removal in the Fuel System chapter Bolts A and Guard B e Remove Bolts A and Screen B e Remove Bolts A Fan Housing B e Remove Ignition Coils A see Ignition Coil Removal Stud Bolts B and Plate Cooling Fan C e Hold the flywheel with a suitable tool A remove the fly wheel bolt B and the
46. conditions 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 PERIODIC MAINTENANCE 2 3 Torque and Locking Agent The following tables lists 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 EO Apply oil to the threads L Apply a non permanent locking agent to the threads R Replacement Parts S Tighten the fasteners following the specified sequence Torque Fastener Nom kaim ftlb Remarks Fuel System Carburetor and Inlet Pipe Mounting Bolts 5 9 0 60 52 in lb Carburetor and Inlet Pipe Mounting Nuts 5 9 0 60 52 mb Air Creaner Bracket Mounting Nuts 19 6 2 00 14 4 Air Creaner Mounting Bracket Bolt 19 6 2 00 14 4 Fuel Pump Mounting Bolts 5 9 0 60 52 mb Inlet Manifold Bolts 5 9 0 60 52 mb S Governor Shaft Plate Screws 2 0 0 20 18 in lb Governor Arm Joint Bolt 5 9 0 60 52 mb Governor Arm Clamp Nut 7 8 0 80 69 in lb Cooling System Engine Shroud Bolts 5 9 0 60 52 in lb Cooling Fan Screen Bolts 5 9 0 60 52 mb Cooling Fan Plate Mounting Stud Bolts 5 9 0 60 52 mb Guard Mounting Bolts 5 9 0 60 52 mb Fan Housing Bolts 5 9 0 60 52 mb Engine Top End Cylinder Head Bolts Rocker Cover Bolts Exhaust Pipe Nuts Valve Clearance Adjusting Locknuts Connecting Rod Big End Cap Bolts Lubricat
47. ctrical System Spark Plug Cleaning and Inspection e Carefully pull the plug cap from the spark plug and re move the spark plug lf the plug is oily or has carbon built up on it clean the RER SR RS WSS S plug using a high flash point solvent and a wire brush or _ BN other suitable tools ES x If the spark plug electrodes are corroded or damaged or WA SSA R27777 EX KKK if the insulator is cracked replace the plug with a new one Use the standard spark plug or its equivalent Insulator A GP100123S1 Center Electrode B Plug Gap C Side Electrode D Spark Plug Gap Inspection e Measure the gap with a wire type thickness gauge x If the gap is not correct carefully bend the side electrode with a suitable tool to obtain the correct gap Spark Plug Gap Standard 0 7 0 8 mm 0 028 0 031 in FUEL SYSTEM 3 1 Fuel System Table of Contents Exploded Mie Wii aaa las ida ab capaci 3 2 eene de 3 4 Governor Link Mecha E 3 5 Control Panel Assembly Removal sen 3 5 Control Panel Assembly Installation lessons rr mnt dE ENNER 3 5 Governor Arm Removal sise 3 6 Governor Arm Installation ereenn a a e e 3 6 Governor Assembly Removal si 3 6 Governor Assembly Installation iaa di 3 7 Governor Assembly Inspection se 3 7 Governor Shaft Remov l erain ss ri ie o Eden 3 7 Governor Shaft Installat
48. d check that the steel balls and governor plate operate freely Governor Assembly Inspection e Visually check all governor parts for wear or damage x If any parts are worm or damaged replace them with new ones Governor Shaft Removal e Split the crankcase see Crankcase Cover Removal in the Camshaft Crankcase chapter e Unscrew the governor shaft plate screws A and pull out the governor shaft B NOTE ORemove the governor shaft only if the replacement of the governor shaft is necessary e Replace the oil seal with a new one only if the lip shows signs of leakage or it has been damaged see Crankcase Cover Assembly in the Camshaft Crankshaft chapter Governor Shaft Installation e Apply engine oil to the governor shaft e Insert the governor shaft A into the crankcase cover e Install the governor shaft plate B to the shaft as shown e Tighten Torque Governor Shaft Plate Screws C 2 0 N m 0 20 kgf m 18 in Ib e Check that the governor shaft moves freely in its operating range 3 8 FUEL SYSTEM Carburetor Fuel and Air Flow The main system of the carburetor consists of the main jet A valve seat B main nozzle C and the main air passage D main air jet E The main system meters fuel to the engine during moderate to heavy load conditions Fuel flows through the main jet and into the main nozzle where it is joined by air from the main air passage main air orifice The resulting
49. e engine is used correctly systematically carry out troubleshooting starting with simple points This chart describes typical troubleshooting procedures Do not unnecessarily disassemble the carburetor the magneto or the engine unless it has been found to be the cause of malfunctioning Engine hard to start NO YES Remove spark plug and check spark by cranking engine while having the plug touched against engine block A WARNING 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 Are sparks produced when spark plug is replaced e Faulty spark plug Replace NO YES Are sparks produced when ignition coil is replaced e Faulty ignition coil Replace Correct e Incorrect air gap e Faulty flywheel Replace e No fuel in the tank Add e Entry of dust or air into fuel Clean pipe or filter ePlugged air hole in tankH Clean Make starting attempts a cap and fuel pump number of times and e Plugged fuel line then remove spark plug and observe electrodes Are they wet Is compression sufficient Clean e Excessive use of choke Remove the plug and turn the crankshaft without loading e Plugged air cleaner Replace elements e Too high fuel level in float Adjust bowl e Worn piston piston rings Replace e Stuck piston rings Clean or r
50. e hard to start e Spark plug fouled pitted or gapped incorrectly e Entry of dust or waiter into fuel pipe or fuel filter e Air or vapor lock in fuel line e Plugged air vent of fuel tank cap e Plugged air fuel passes in carb e Too little opening of carb pilot screw e Carb not properly adjusted e Carb flange leaking at gasket eWorn carb body and throttle shaft Adjust level Adjust level or add Decrease load Adjust Clean Clean Replace Replace Replace Adjust gap Correct Change Replace Replace Replace Clean Replace Clean Adjust Adjust level Replace Replace Replace or adjust Clean Clean Clean Clean Correct Adjust Tighten or replace Adjust level KI02062B F 10 4 TROUBLESHOOTING Engine Troubleshooting Guide Problem in the governor system e Incorrect governor linkage Correct adjustment e Faulty governor spring Replace e Governor assy malfunctioning Check Engine malfunctions at high speed Is revolution fluctuation of relatively YES e Plugged air hole in tank cap Clean large period produced when a load is e Entry of dust and air into fuel Clean applied filter or fuel pipe Engine malfunctions at low speed Remove spark plug and check spark by WEAK e Faulty plug insulation Replace e Fouled electrodes Clean e Faulty ignition coil Replace e Incorrect air gap Correct cranking engine while having the plug touched against engine b
51. e replaced 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 Unregulated Stator Output e Disconnect the connector A e Connect AC voltmeter to the stator pins B e Start the engine Run the engine at the 3 000 rpm speed e Voltage reading should be minimum 26 V AC 3 000 rpm x lf the AC voltage reading is less than the specification replace the stator with a new one Unregulated Stator Output MIN 26 V AC 3 000 rpm Regulator Removal e Remove Stator Coil Lead Connector A Regulator Screws B Regulator C Regulator Installation e Install the regulator A and tighten the screws B Torque Regulator Screws 3 5 N m 0 36 kgf m 31 in Ib e Apply grease Three Bond TB2585G to the regulator terminals C e Connect the stator coil lead connector D 9 12 ELECTRICAL SYSTEM Charging System Regulator Resistance e Remove the regulator see Regulator Removal e Set the KAWASAKI Hand Tester selector switch to the R x 100 Q position e Connect the test leads to the points shown on the chart and read the resistance Without Charging Monitor Type 3 Blades A B e KHO7042BS1 A S co co B co 0 C co 0 SS D over than over than over than 1 MQ 1 MQ 1 MQ NOTE OResistance value may vary with individual meter
52. ealing surfaces should be smooth and free of burns and nicks Replace the gasket with a new one 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 with new ones e Check the gasket on the carburetor body x If the gasket is not in good condition replace it with a new one e Check the other parts of the carburetor for any wear or damage Replace the part with a new one 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 eye level Gently support the float with a finger and bring it down slowly so that the float arm tab C just touches the float valve D The float lower surface E should be parallel with the carburetor body mating surfaces F x lf the float position is not correct replace the float with a new one 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 pushed in and released A Good B Not Good x If either the needle or the seat is worn or damaged re place the float assembly and carburetor body as a set w
53. eat cutter or the diamond particles may fall off 3 Be sure 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 5 After use wash the cutter with washing oil and apply thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter represent the following 32 Cutter angle A 37 5 Cutter diameter B KS8B Manufactured lot number Operating Procedures e Clean the seat area carefully e Recondition the valve seats with the valve seat cutters 45 32 and 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 greater than the STD width reface the seating surface x If the valve seating pattern is not correct repair the seat KEO5016BS1 KMO7011BS1 C PERIODIC MAINTENANCE 2 13 Periodic Maintenance Procedures e Coat the seat with machinist s dye e Fi
54. ed 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 lf fuel flow is none or little replace the fuel pump with a new one Check the tubes and the fuel filter for clogging or damage Replace the clogged or damaged tubes of fuel filter with new ones 3 20 FUEL SYSTEM Fuel Pump Fuel Filter Fuel Filter Removal Installation e Remove Clamp A Fuel Filter B e When install the fuel filter arrow mark C faces fuel pump side 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 replacement of the fuel filter is not necessary x If the filter is dark or looks dirty replace it with a new one Also check the rest of the fuel system for contamination Air Cleaner FUEL SYSTEM 3 21 Element Removal e While pulling up the two knobs A turn the cap B to counterclockwise e Align the arrow mark A and unlock mark B to remove the cap e Remove Primary Element A e Remove Secondary Element A Element Installation e Slide the secondary element and primary element into place in the air cleaner body e Align the arrow mark A on the body and unlock mark B
55. elect an arbor of the same diameter of 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 height difference of the small end arbor on the surface plate Using a dial gauge measure the height at two different positions and the distance of the two positions is 100 mm 3 94 in B Then deter mine the connecting rod bent from the measured height differences C x If connecting rod bend exceeds the service limit replace the connecting rod with a new one Connecting Rod Bend Service Limit 0 15 100 mm 0 006 3 94 in e Measure the connecting 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 difference Using a dial gauge measure the height at tow different positions and the distance of the two positions is 100 mm 3 94 in A Then deter mine the connecting rod twist from the measured height differences B x If connection rod twist exceeds the service limit replace the connecting rod with a new one Connecting Rod Twist Service Limit 0 15 100 mm 0 006 3 94 in Connecting Rod Big End Crankpin Width Wear e Measure the connecting rod big end width A with a mi crometer or a dial caliper x If the measurement is less than the service limit
56. ember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In preparing this manual we divided the prod uct into its major systems These systems be came the manual s chapters All information for a particular system from adjustment through disassembly and inspection is located in a sin gle chapter The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Table of Contents The Periodic Maintenance Chart is located in the General Information chapter The chart gives a time schedule for required maintenance operations If you want spark plug information for exam ple go to the Periodic Maintenance Chart first The chart tells you how frequently to clean and gap the plug Next use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chapter to find the Spark Plug sec tion 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
57. eplace e Worn cyl bore Replace e Insufficient cyl head Retighten tightening Check for plugged fuel e Faulty contact of valve Lap line seat Check for plugged air e Plunge up by valve Adjust valve clearance passage e Warped cyl head Replace Check float level e Broken valve spring Replace Check carb setting e Stuck valve Clean or replace e Burned head gasket Replace Check carburetor KI02036B_F Engine Troubleshooting Guide TROUBLESHOOTING 10 3 Engine power loss Is engine overheated Is the ignition spark normal Is lubricating condition normal Is unusual smoke emitted out of muffler Is compression sufficient Engine runs erratically Problem in the fuel system lack of fuel YES NO NO NO NO eCrankcase low on oil e Too much oil in crankcase e Excessive engine load e Carb not properly adjusted e Carbon deposit in combustion chamber e Clogging of cooling system e Damaged cooling fan e Wrong spark plug e Faulty ignition coil eIncorrect air gap e Too much or too little oil in crankcase Excessively contaminated lubricating oil e Defective oil filter e Faulty relief valve e Faulty oil pump e Clogging oil system e Plugged air cleaner elements e Carbon deposit in exhaust hole and muffler e Carb not properly adjusted e Too much oil in crankcase e Worn piston piston rings e Worn cylinder bore e See Engin
58. er 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 29 5 mm 1 16 in Service Limit 29 0 mm 1 14 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 GP11061081 C KHO9013BS1 6P110607581 KHOS014BS1 8 12 STARTER SYSTEM Electric Starter System e Measure the armature winding resistance OSet the multimeter selector switch to the R x 1 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 e Set the multimeter selector switch to the R x 1 kO 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 dell 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
59. er circumference so that it will go into place smoothly 11 Ball Bearing When installing a ball bearing the bearing race which is affected by friction should be pushed by a suitable driver This prevents severe stress on the balls and races and prevents races and balls from being dented Press a ball bearing until it stops at the stop in the hole or on the shaft 12 0il Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally dam ages seals 4 7 8 x 9 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 Replace any circlips and retaining rings that were removed with new ones as removal weakens and deforms them When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more 15 Cotter Pin Replace any cotter pins that were removed with new ones as removal de
60. for the equip ment used in the high altitude The main jet numbers are stamped on the ends of the main jets High Altitude Main Jet Altitude Main Jet No L 134 0 1 000 m 0 3 000 ft R 140 L 131 1 000 2 000 m 3 000 6 000 ft R 137 L 128 2 000 m 6 000 ft and higher R 134 Main Jet Replacement e Close the fuel shut off valve in the equipment e Remove the carburetor see Carburetor Removal e Drain the fuel in the carburetor completely by unscrewing the drain screw at the bottom of the float chamber see Fuel System Cleanliness Inspection in the Periodic Main tenance chapter e Unscrew the chamber screws A and take off the float chamber B KCO5152BS1 o FUEL SYSTEM 3 11 Carburetor e Remove the float assembly A from the float chamber Kco5BI01 P e Remove Pin A Float B Float Valve C Spacer D O ring E E KC05137BS1 o e Use the rod to push the main jet L A and R B out from the bottom side of the spacer C e Replace the main jet A with a new one for altitude ex pected see High Altitude Operation e Install the new O ring B to the main jet e Using the rod C press the main jet until they are bot tomed to the spacer D e Assemble the carburetor see Carburetor Disassem bly Assembly KCO5138BS2 Fuel System Cleanliness Inspection e Refer to the Fuel System Cleanliness
61. forms and breaks them 16 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film During assembly oil or grease whichever is more suitable should be applied to any rubbing surface which has lost its lubricative film Old grease and dirty oil should be cleaned off Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles Don t use just any oil or grease Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended This manual makes reference to molybdenum disulfide grease MoS2 in the assembly of certain engine parts Always check manufacturer recommendations before using such special lubricants 17 Electrical Wires All the electrical wires are either single color or two color and with only a few exceptions must be connected to wires of the same color On any of the two color wires there is a greater amount of one color and a lesser amount of a second color so a two color wire is identified by first the primary color and then the secondary color For example a yellow wire with thin red stripes is referred to as a yellow red wire it would be a red yellow wire if the colors were reversed to make red the main color Wire cross section Color Indicated on the Wire Color Indicated on the Wiring Diag
62. fuel tube D fully so that the clamp knob E face horizontal direction e Apply grease Three Bond TB2585G to the solenoid valve terminal e Connect the solenoid valve connector e Install the air cleaner see Air Cleaner Body and Bracket Installation e After installation adjust the idle speed see Low Hight Idle Speed Adjustment in the Periodic Maintenance chapter Carburetor Disassembly Assembly e Refer to the illustration shown for disassembly and as sembly OThere are several passage plugs Ball plugs in the car buretor body Do not remove e Before disassembly mark the outside of choke valve and throttle valves for assembling them 1 Pilot Screw Plug 16 O rings 2 Pilot Screw 17 Gasket 3 Screws 18 O ring 4 Cover Plate 19 Spacer 5 Gasket 20 Pin 6 Screws 21 Float Valve 7 Choke Valve 22 Float 8 Choke Shaft 23 O ring 9 Seal 24 Gasket 10 Screws 25 Screws 11 Throttle Valves 26 Solenoid Valve 12 Throttle Shaft 27 Gasket 13 Seal 28 Spring 14 Main Jet L 29 Drain Screw 15 Main Jet R 30 Spring Screw O87 QO f dl Delt T1 KCO5149BS2 C KC05139BS3 C 3 14 FUEL SYSTEM Carburetor e Replace the pilot screw A in accordance with the follow ing procedure if necessary ORemove the pilot screw plug B material Stainless steel as follows Punch a hole in the plug and pry it out with an awl or other suitable tool OTurn in the pilot screw and count
63. gauge to measure front to back and side to side at the points as shown in the figure lf any of the cylinder inside diameter measured value is greater than the service limit replace the crankcase with a new one A 10 mm B 55 mm C 25 mm Cylinder Inside Diameter Standard 89 13 89 15 mm 3 509 3 510 in Service Limit 89 23 mm 3 513 in Cylinder Inside Diameter Out Round Service Limit 0 05 mm 0 002 in Oo KEO6091BS1 C KEO6092BS1 o LUBRICATION SYSTEM 6 1 Lubrication System Table of Contents leie e WEE 6 2 Engine Oil Flow C E 6 4 ele ee 6 5 Special TOONS A seven sauananvacetbacevaaeteedueghluaseenendaveedaadedes Mr at ram ra nt 6 6 Engine Oil Oil Filter and Oil Cooler eee 6 7 Engine Oil Level Inspection cx cccsccccscceencceseesacetecencesenyenss odon dci 6 7 Engine Qil CAMI A A As 6 7 DEE EAEN I ETIT TEE ET ltdacadidsad rec iron its cerise 6 7 OIE en Installation da deve cds A AT E daa AEN 6 7 Oil Cooler Removal dol Ret ee ace EN 6 7 Oil Cooler Installation a nunnan nenn 6 7 Oil Cooler Lu Re NO E A AT 6 7 Pressurized Lubrication System cutis online reee teintes 6 8 Oil Pressure Measurement 6 8 QILPUMp Relief Valve EE EELER SES SEENEN EES 6 9 Oil Pump Relief Valve Removal A a 6 9 Oil Pump Relief Valve Installation 6 9 Oil Pump Relief Valve Inspechon 6 10 Teen DEE 6 12 Oil Screen Removal iii a ee diene eine 6 12 Oil Screen Installation ds
64. h the piston ring end gap as shown Arrow Match Marks A Top Ring End Gap Upper Steel Rail End Gap B About 45 C Second Ring End Gap Lower Steel Rail End Gap D e Apply engine oil to the piston pins e Assemble the pistons onto the connecting rods No 1 cylinder piston align the arrow match mark on the piston head with opposite K Mark on the connecting rod to face the flywheel side No 2 cylinder piston align the arrow match mark on the piston crown with the K mark on the connecting rod Both marks must face the flywheel side No 1 cylinder Piston A No 2 cylinder Piston B Arrow Match Marks C K Mark D Opposite K Mark E 6E16060651 KE06045B51 Za R KEO6O087BS1 C Cylinder Piston ENGINE TOP END 5 17 e When installing a piston pin snap ring compress it only enough to install it Do not compress the piston pin snap ring too hard 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 on 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 Apply engine oil to the piston skirt and the cylinder bore x Using the piston ring compressor grip A and the belt B lightly tap the top of the piston with a plastic mallet C to insert the piston and connecting rod into the cy
65. han the ser vice limit replace the piston with a new one Piston Ring Groove Clearance Service Limit Top Second 0 18 mm 0 0071 in NOTE OThe oil ring is a three piece assembled ring It is diffi cult to measure the ring groove clearance and the thick ness Visually inspect the oil ring the ring groove clear ance and the oil ring thickness e Measure the piston ring thickness A OUse a micrometer to measure the ring thickness at several points around the rings x If any of the measurement are less than the service limit replace the entire set of rings with new ones Piston Ring Thickness Service Limit Top Second 1 90 mm 0 0748 in NOTE OWhen using new rings in a used piston check if the groove wear is even The rings should fit perfectly par allel to the groove sides If not replace the piston with a new one KE06038B51 KE06039BS51 KE06010B51 C 5 20 ENGINE TOP END Cylinder Piston Piston Ring End Gap e Remove the piston rings e Push each ring one at a time in the cylinder bore to a point close to the bottom of the cylinder bore OUse the piston to push it in to be sure it is square e Measure the gap A between the ends of the ring B with a thickness gauge x If the end gap of any ring is greater than the service limit replace the entire set of rings with new ones Piston Ring End Gap Service Limit Top 0 7 mm 0 028 in Second 0 8 mm 0 03
66. hange in the Periodic Main tenance chapter e Remove Camshaft see Camshaft Tappet Removal Connecting Rod and Piston Assembly see Piston Re moval in the Engine Top End chapter e Pull the crankshaft A out of the crankcase OTap 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 amount of high temperature grease into the oil seal on the crankcase e Apply engine oil to the crankshaft journal and ball bearing e Carefully insert the crankshaft end into the main bearing and the oil seal in the crankcase Cleaning Inspection e After removing clean the crankshaft and the connecting rods with a high flash point solvent and dry them with compressed air e Inspect the teeth of the crankshaft gear for pitting fatigue cracks burrs and any evidence of improper tooth contact x Replace the gear with a new one if necessary e Inspect the crankshaft and connecting rods especially at the bearing surfaces for wear scratches any evidence of improper contact or other damages Replace them with new ones if necessary 7 18 CAMSHAFT CRANKSHAFT Crankshaft Connecting Rod Connecting Rod Bend Twist e Measure the connecting rod bend OSelect an arbor A ofthe same diameter ofthe connecting rod big end and insert the arbor through the connecting rod big end OS
67. he suitable tool and remove it e Pry the crankshaft oil seal with the suitable tool and re move it e Remove the ball bearing Special Tool Oil Seal amp Bearing Remover 57001 1058 Crankcase Cover Assembly e Chip 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 the cover and wipe them dry 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 KGOSBOJ7 P CAMSHAFT CRANKSHAFT 7 7 Crankcase e Be sure to replace the ball bearing with a new one if re moved e Press the ball bearing A until bottom surface B of the crankcase cover Special Tool Bearing Driver Set 57001 1129 e Apply engine oil to the ball bearing e Be sure to replace any oil seal with a new one if removed e Apply mineral oil to the crankshaft oil seal outside e Install the oil seal so that the marks A face out e Pack some amount of high temperature grease B into the space between the seal lip C and the dust lip D e Press in the new oil seal using a press or suitable tools until it is flush or belo
68. ia ab eras 4 2 Cooling Fan EE 4 4 Cooling Fam Removal EH 4 4 Cooling Fan installation dd io pias 4 4 Cooling Fam INSPSCHON EE 4 4 Engine Shroud BE 4 5 AR Engine Shroud Removal Installation 4 5 4 2 COOLING SYSTEM Exploded View COOLING SYSTEM 4 3 Exploded View Fastener a Remarks 1 Engine Shroud Bolts 5 9 0 60 52 in lb 2 Cooling Fan Screen Bolts 5 9 0 60 52 mb 3 Cooling Fan Plate Mounting Stud Bolts 5 9 0 60 52 mb 4 Guard Mounting Bolts 5 9 0 60 52 mb 5 Fan Housing Bolts 5 9 0 60 52 mb 4 4 COOLING SYSTEM Cooling Fan Cooling Fan Removal e Refer to the Flywheel and Stator Coil Removal in the Elec trical System chapter Cooling Fan Installation e Refer to the Flywheel and Stator Coil Installation in the Electrical System chapter Cooling Fan Inspection e Remove the fan housing see Flywheel and Stator Coil Removal in the Electrical System chapter e Visually inspect the blades A in the cooling fan x If they have any crack warp or damage replace the cool ing fan with a new one If any mud or dust have stuck to the cooling fan clean it e Wash the cooling fan in detergent and water CAUTION Do not clean the cooling fan in oil solvent It may be damage by oil solvent COOLING SYSTEM 4 5 Engine Shroud Engine Shroud Removal Installation e Remove Fan Housing see Flywheel and Stator Coil
69. idle speed and leave it there High Idle Speed 3 600 rpm e Turn the high idle set screw B so that the end of it just touches the speed control lever C and tighten the lock nut A e Check the idle speed and readjust the idle speed if nec essary CAUTION Be sure to make the idle and fast idle speeds re spectively correspond to those of the equipment Fuel System Cleanliness Inspection 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 Place a suitable container A under the drain screw B on the carburetor e Turn out the drain screw a few turns to drain the carbu retor and check if water or dirt has accumulated in the carburetor e Tighten the drain screw elf any water or dirt is found clean the carburetor see Carburetor Cleaning in the Fuel System chapter and fuel tank And check the fuel filter Element Cleaning and Inspection Air cleaner elements are not recommended to be cleaned and each air cleaner element should be replaced with new ones at the maintenance time as shown in the maintenance Chart NOTE OOperating in dusty condition may require more frequent maintenance than above e Remove the elements see Element Removal in the Fuel System chapter e Replace the prima
70. imary Winding Resistance Secondary Winding Resistance Spark Plug Plug Gap 0 2 0 4 mm 0 008 0 016 in in the text in the text NGK BPR5ES 0 7 0 8 mm 0 028 0 031 in ELECTRICAL SYSTEM 9 5 Special Tool Hand Tester 57001 1394 9 6 ELECTRICAL SYSTEM Wiring Dagram Note Portion surrounded by shows KHI procurement parts Spark Plugs SC Voltage Regulator Color Code Battery START ototo E pi KH04032BW4 C Precautions ELECTRICAL SYSTEM 9 7 There are a number of important precautions that you must follow when servicing electrical systems Learn and observe all the rules below ODo not reverse the battery cable connections This will burn out the diodes in the electrical parts OAlways check the battery condition before judging other parts of the electrical system A fully charged battery is necessary for conducting accurate electrical system tests ODo not hit the electric parts with a hammer or do not drop the electric parts These may result in the electric parts damage or breakage OTo prevent damage to electrical parts do not disconnect the battery cables 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 start or the current m
71. in Wear 7 19 Crankshaft RUNGU T serie aE oa aAa a idea 7 19 Grankshaft Journal Near ne none nn Re a a a nt 7 20 7 2 CAMSHAFT CRANKSHAFT Exploded View CAMSHAFT CRANKSHAFT 7 3 Exploded View Fastener Remarks 1 Oil Passage Plugs 3 9 0 40 34 in lb L 2 Crankcase Cover Bolts 46 4 7 34 S 3 Connecting Rod Big End Cap Bolts 20 6 2 10 15 2 EO 4 Breather Valve Mounting Screws 2 0 0 20 18 in lb 5 Breather Chamber Cover Bolts 5 9 0 60 52 mb 6 Breather Pipe Cover Bolts 5 9 0 60 52 in lb EO Apply engine oil G Apply grease L Apply a non parmanent locking agent Mi Apply mineral oil MO Apply molybdenum disulfide oil R Replacement Parts S Tighten the fasteners following the specified sequence 7 4 CAMSHAFT CRANKSHAFT Specifications Item Service Limit Camshaft Tappet Cam Lobe Height Inlet 34 49 mm 1 358 in Exhaust 35 11 mm 1 382 in Camshaft Journal Diameter PTO Side 19 98 mm 0 7866 in Camshaft Bearing Inside Diameter Crankcase 20 14 mm 0 7929 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 0 15 100 mm 0 006 3 94 in 0 15 100 mm 0 006 3 94 in 22 70 mm 0 8937 in 49 0 mm 1 93 in 42 04 mm 1 655 in 41 94 mm 1 651 in TI
72. in dam age to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of informa tion NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a WARNING CAU TION or NOTE x Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view 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 A WEE EE Model Identifications EE General Specifications 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
73. ion System Oil Filter Joint Pipe 6 9 0 70 61 in lb Oil Pump Cover Plate Bolts 5 9 0 60 52 in lb Oil Filter 11 8 1 20 104 in lb R Engine Oil Drain Plugs 6 9 0 70 61 in lb EO Oil Filler Mounting Bolt 5 9 0 60 52 mb Oil Cooler Bolts 5 9 0 60 52 mb Camshaft Crankshaft Breather Valve Mounting Screws Breather Chamber Cover Bolts Crankcase Cover Bolts Oil Passage Plugs Connecting Rod Big End Cap Bolts Starter System Starter Motor Mounting Bolts 19 6 2 00 14 4 2 4 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Nem kg ftIb Remarks Electrical System Ignition Coil Bolts 6 9 0 70 61 in lb Stator Coil Screws 3 4 0 35 30 in lb Flywheel Bolt 56 5 7 41 Regulator Screws 3 5 0 36 31 in lb Spark Plugs 22 2 2 16 Fan Housing Bolts 5 9 0 60 52 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 dia mm 17 in lb 0 35 30 in lb 0 60 52 in lb 1 5 11 Specifications PERIODIC MAINTENANCE 2 5 Standard Fuel System Idle Speed 1 Low Idle Speed Carburetor idle rom 1 450 r min rpm Low Idle Speed Governor idle rpm High Idle Speed Air Cleaner Type Pre cleaner Second stage clea
74. ion ss 3 7 Carreta 3 8 Fueltand Alr FlOW EE 3 8 Fuel Shut Off Solenoid Valve ooooooociiociconicocncoiccccccccccncn nr 3 10 Low idle Speed AdJUSIMO diri a STARS ata 3 10 High Idle Speed Adjustment miccional enke dE ebe e 3 10 RIA A ted mi AA AAS ANESSE Ea 3 10 Main Jet Replacement ie 3 10 Fuel System Cleanliness Inspection 3 11 Carburetor Remova see 3 12 Carburetor Installation a dee REENEN 3 12 Carburetor Disassemblhvl Assembhy nana n nn nnnnnnn nn nnnnnnn cnn 3 13 Carburetor Clear A ecko tues Retina nee iu cade 3 15 Carburetor inspector iz 3 16 Fuel Shut Off Solenoid Valve Test 3 17 Inlet MANOA BEE 3 18 Inlet Manifold Removal sise 3 18 Inlet Manifold Installation til ea 3 18 Inlet Manifold Inspection 3 18 Fuel Pump FUESEN erica a A a AI ele cs EA E 3 19 Fuel Pump Removal sise 3 19 Fuel Pump Installation AAA ent rente 3 19 Fuel Pump Inspection ss 3 19 Fuel Filter Removal Installation renere ne 3 20 Fuel Filter Inspecton rn 3 20 ANLE CT TEI AE E as 3 21 Element ROMO iii A A a e a EA ee 3 21 Element Installations ss r a a r ee tab 3 21 Element Cleaning and Inspection ET 3 22 Air Cleaner Body and Bracket Removal ooooooocccccccccccccoonccononoconononanannnnnnnncncnnnan ono nnnnnnnnnnns 3 22 Air Cleaner Body and Bracket Installation AAA 3
75. ith a new one KCO5118BS1 o KCGO5011BS1 FUEL SYSTEM 3 17 Carburetor e Inspect the tapered portion A of the pilot screw B for wear or damage x If the pilot screw is worn or damaged on the taper portion replace it with a new one e Check the spring condition replace it with a new one if necessary Fuel Shut Off Solenoid Valve Test e Unscrew the fuel shut off valve A and remove it e Connect a 12 VDC source to the solenoid as shown x lf the actuated solenoid plunger Needle Valve does not pop out when the Test Voltage is applied replace it with a new one NOTE Olf necessary push the plunger slightly for the plunger to withdraw KCO5113BS1 3 18 FUEL SYSTEM Inlet Manifold Inlet Manifold Removal e Remove Fan Housing see Flywheel and Stator Coil Removal in the Electrical System chapter Carburetor see Carburetor Removal e Cut offthe bands A holding the wire lead and or harness e Unscrew the inlet manifold bolts in the order shown 1 to 6 e Remove Inlet Manifold B Inlet Manifold Installation e Replace the inlet manifold gaskets A with new ones e Clean the mating surfaces of the cylinders and Inlet man ifolds e Install the inlet manifold gasket so that the hole B of the gasket fit the projection C of the cylinder head e Tighten the inlet manifold bolts following the tightening sequence Torque Inlet Manifold Bolts 5 9 N m
76. ized 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 returns to the crankcase A pressure relief valve is used between the oil pump and oil filter to relieve excessive oil pressure by returning excessive oil to the crankcase see Oil Flow Chart Oil Pressure Measurement e Remove the oil passage plug A from the crankcase e Install the oil pressure gauge adapter A and oil pressure gauge B Special Tools Oil Pressure Gauge 10 kgh cm 57001 164 Oil Pressure Gauge Adapter PT 1 8 57001 1033 e Run the engine and warm up thoroughly e Run the engine at high idle speed and read the oil pres sure gauge Oil Pressure 294 to 490 kPa 43 to 71 psi Measurement Condition Engine Oil Temperature 50 60 C 122 144 F e Stop the engine e Remove the oil pressure gauge and the adapter e Apply a non parmanent locking agent to the oil passage plug and tighten it Torque Oil Passage Plug 3 9 N m 0 40 kgf m 34 in Ib x lf the measured oil pressure is below the specification inspect the oil pump and the relief valve x If the oil pump and the relief valve are not at fault inspect the rest of the lubrication system LUBRICATION SYSTEM 6 9 Oil Pu
77. linder Special Tools Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 80 91 57001 1320 e Insert the piston and the connecting rod so that the arrow match mark A on the piston crown faces the flywheel side B 5 18 ENGINE TOP END Cylinder Piston 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 molybdenum disulfide oil solution oil to the inner surface A of the connecting rod big end B and caps C OThe molybdenum disulfide oil solution is a mixture of en gine oil and molybdenum disulfide grease with a weight ratio 10 1 e Install the connecting rod big end caps on their original position on each connecting rod big ends e Apply a thin layer of engine oil to the thread D and seat ing surface E of the cap bolts e Tighten the cap bolts Torque Connecting Rod Big End Cap Bolts 20 6 N m 2 10 kgf m 15 2 ft lb e Install Camshaft see Camshaft Tappet Installation in the Camshaft Crankshaft chapter Crankcase Cover see Crankcase Cover Removal in the Camshaft Crankshaft chapter Piston Cylinder Seizure e In case of seizure remove the pistons e Visually inspect the cylinder and pistons for damage x lf there is only light damage repair the damaged piston surface with 400 emery cloth Remove the small alu minum deposits from the cyli
78. lock STRONG AWARNING Keep the plug as far away as possible from the plug hole To avoid an electric shock do not hold the plug itself Make sure to hold the plug cap Is unusual smoke emitted out of YES e Overrich fuel in pilot system Turn in pilot screw muffler by a minor extent NO Directly and gradually open throttle YES e Plugged in carburetor interior Disassemble and clean valve by hand Does the revolution a NO drop or does engine stall at a certain position e Loose flange nuts Retighten eDamaged gasket Replace Is air sucked through carburetor flange Are valve clearances of normal values NO e Compression leakage Adjust valve clearance e Wrong valve timing Correct alignment of timing gear marks Is alignment of timing gear marks NO e Largely deviated valve timing Correct alignment of correct timing gear marks KI02063B F Engine Troubleshooting Guide TROUBLESHOOTING 10 5 Fuel consumption is excessive Is compression sufficient YES NO Oil consumption is excessive Is compression sufficient YES NO Engine backfires Engine knocks e High fuel level in carb float chamber including overflow e High idling PR PM e Choke partially closed e Excessively backed off carburetor pilot screw e Worn piston piston rings e Stuck piston eWorn cylinder bore e Insufficient cyl head tightness e Faulty valve seat contact ePlunge up of valve e W
79. lock see Cylinder Head Assembly In stallation in the Engine Top End chapter e Turn the crankshaft in proper direction until the piston is at the TDC of the compression stroke as described above e Loosen the adjusting screw A with a suitable tool B e Loosen the valve clearance adjusting locknut C e Insert a 0 10 mm 0 04 in thickness gauge D between the rocker arm and valve stem Tighten the adjusting screw until the thickness gauge begins to bind between the rocker arm and valve stem end Sweep the thickness gauge during this adjustment Valve Clearance when cold Inlet Exhaust 0 10 0 15 mm 0 0039 0 0059 in KMO7012BS1 C Y fe KMO7013BS1 C 16078045 P PERIODIC MAINTENANCE 2 11 Periodic Maintenance Procedures e Holding the adjusting screw with a suitable tool tighten the adjusting locknut A to the specified torque Torque Valve Clearance Adjusting Locknuts 9 8 N m 1 0 kgf m 87 in lb e Do not overtighten the valve clearance adjusting locknuts e After the valve clearance adjustment measure the valve clearance again Readjust the valve clearance if neces sary 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 lf the seats are warped or distorted beyond recondition ing replace the cylinder head with a new one e Pitted or worn valve seats can be ref
80. lowed 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 to reinstall in their original position during assembly ENGINE TOP END 5 9 Cylinder Head Cylinder Head Assembly Installation e Clean the mating surfaces of the cylinder heads and cylin ders e Install the push rods in their original positions on each cylinder see Push Rod Installation e Install the knock pins A e Set each piston at the T D C A of the compression stroke e Put new gaskets and the cylinder head assemblies on each cylinder then let the cylinder heads with push rods aligned under the rocker arms NOTE OAs the head gaskets are coated with sealing agents be careful not to damage the surfaces e Tighten the cylinder head bolts following the tightening sequence as shown A 1 Cylinder B 2 Cylinder Torque Cylinder Head Bolts 46 N m 4 7 kgf m 34 ft Ib CAUTION A torque wrench must be used to assure proper torque Improper tightening of the head bolts may result in warping of the cylinder head e Install Rocker Arms A Rocker Shafts B e Check to see that push rod ends are in the hollow of the rocker arms e Check and adjust the valve clearance e Install the new gaskets and rocker covers Torque Rocker Cover Bolts 5 9 N m 0 60 kgf m 52 in Ib e Install the other
81. lve into seat with a lapper e Coat the valve face sparingly with a fine lapping com pound e Use the lapper A to grip the 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 14 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 lapping mark should appear on or near the center of the valve face e When the engine is assembled be sure to adjust the valve clearances see Valve Clearance Adjustment Lubrication System Engine Oil Level Inspection e Place the engine on a level surface e Remove the oil filler cap A and wipe its dipstick B with a clean cloth e Insert the dipstick into tube C without screwing it in then check the oil level e The oil level should be the operating range A grid area on the dipstick D x If the oil level is ADD range B add enough engine oil to bring oil level to the operating range CAUTION Do not add more oil above the operating range Ex cess oil will cause a smoking condition OUse the same type and make of oil that is already in the engine NOT
82. m Rocker Arm Inside Diameter Service Limit Inlet Exhaust 12 05 mm 0 4744 in KE04034BS1 C Valves ENGINE TOP END 5 13 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 Removal Instal lation e Measure the valve head thickness x If the valve head thickness valve margin A is less than the service limit replace the valve with a new one Valve Head Thickness Service Limit Inlet Exhaust 0 4 mm 0 016 in Valve Stem Runout e Support the valve on V blocks at each end of the stem e Position a dial gauge perpendicular to the stem e Turn the valve and read the variation on the dial gauge x If the stem runout is greater than service limit replace the valve Valve Stem Runout Service Limit Inlet Exhaust 0 05 mm 0 002 in Valve Stem Diameter e Measure the diameter of the valve stem A in two direc tions at proper angles at four different positions on the stem lf any single measured valve stem diameter is less than the service limit replace the valve with a new one
83. m 0 008 in Rocker Shaft Outside Diameter Inlet Exhaust 11 95 mm 0 4705 in Rocker Arm Inside Diameter Inlet Exhaust 12 05 mm 0 4744 in Cylinder Piston Piston Diameter 88 93 mm 3 501 in Piston Ring Groove Clearance Top 0 18 mm 0 0071 in Second 0 18 mm 0 0071 in Piston Ring Thickness Top Second 1 90 mm 0 0748 in Piston Ring End Gap Top 0 7 mm 0 028 in Second 0 8 mm 0 031 in Oil 1 0 mm 0 039 in Piston Pin Outside Diameter 20 96 mm 0 8252 in Piston Pin Hole Inside Diameter 21 08 mm 0 8299 in Connecting Rod Small End Inside Diameter 21 06 mm 0 8291 in Cylinder Inside Diameter 89 23 mm 3 513 in Cylinder Inside Diameter Out Round 0 05 mm 0 002 in Specifications ENGINE TOP END 5 5 Item Standard Valve Clearance Inlet Exhaust Valve Seating Surface Angle Inlet Exhaust Valve Seating Surface Width Inlet Exhaust Inlet Exhaust Cylinder Inside Diameter Valves Guide Inside Diameter 0 10 0 15 mm 0 0039 0 059 in 45 0 7 1 1 mm 0 028 0 043 in 1 0 1 5 mm 0 039 0 059 in 6 000 6 015 mm 0 2362 0 2368 in 7 000 7 015 mm 0 2756 0 2762 in 89 13 89 15 mm 3 509 3 510 in 5 6 ENGINE TOP END Special Tools Piston Ring Pliers 57001 115 ST5701158T Compression Gauge 20 kgf cm 57001 221 T5702218T Piston Ring Compressor Grip 57001 1095 ST5710958T
84. m 34 ft lb ODo not turn one screw down completely before the others as it may cause the crankcase cover to warp Crankcase Assembly e Remove the old gasket from the mating surfaces of the crankcase and cover e Using compressed air blow out the oil passage in the crankcase e With a high flash point solvent clean off the mating sur faces of the crankcase and the cover and wipe them dry 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 CAMSHAFT CRANKSHAFT 7 9 Crankcase e Be sure to replace the bearings and snap ring with new ones if removed e Install the bearings A so that the bearing notch direction and depth as shown e Install the new snap rings B C 80 D 100 E 3 0 3 2 mm 0 118 0 126 in e Be sure to replace the oil seal with a new one if removed e Apply mineral oil to the crankshaft oil seal outside e Install the oil seal so that the marks A face out e Pack some amount of high temperature grease B into the space between the seal lip C and the dust lip D e Press in the new oil seal using a press or suitable tools until it is flush or below the flange surface E as shown e Do not damage the seal lips F 0 1 mm 0 0 0
85. mit 20 6 mm 0 811 in KFOTBOSD P KFOTBOE P 6 12 LUBRICATION SYSTEM Oil Screen Oil Screen Removal e Remove the oil pump cover plate see Oil Pump Relief Valve Removal e Remove the oil screen A Oil Screen Installation e Clean the oil screen thoroughly whenever it is removed for any reason e Insert the oil screen A in position and install the oil pump parts assembly see Oil Pump Relief Valve Installation Cleaning and Inspection e Clean the oil screen A with high flash point solvent and remove any particles on 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 it with a new one KFOGBOIG P CAMSHAFT CRANKSHAFT 7 1 Camshaft Crankshaft Table of Contents EXDIOde TE EE 7 2 eigene e 7 4 Special Tools and Sealant 0000nnaeeeeeeee eeaeee eent neer nee rnent aer reerreenraenraen raent aearaenneenreennaenr nenene 7 5 CANAS AA A 7 6 Crankcase Cover Remova see 7 6 Crankcase Cover Disassembly cocida diia 7 6 Grankcase Cover Assembly
86. mp Relief Valve Oil Pump Relief Valve Removal e Remove Crankshaft see Crankshaft Removal in the Camshaft Crankshaft chapter Bolts A e Take out the pump cover plate B pump gear C and pump shaft D as a set e Remove the pins A oil pump cover plate B and oil pump gear C from the pump shaft D e Remove Inner Rotor A Outer Rotor B Spring C Relief Valve Ball D Oil Pump Relief Valve Installation e Install the oil screen see Oil Screen Installation e Assemble the following parts as shown Pins A Oil Pump Gear B Oil Pump Cover Plate C Pump Shaft D KFO7009BS1 o e Fill the rotor housing with engine oil for initial lubrication e Install the outer A and Inner rotor B e Install the relief valve ball and spring in position e Fit the pin C of the pump parts assembly D into the slots E in the inner rotor NOTE OWhen installing the pump parts assembly align the 6 mm 0 2 in hole F on the cover plate with center of the relief valve G e Tighten Torque Oil Pump Cover Plate Bolts 5 9 N m 0 60 kgf m 52 in lb 6 10 LUBRICATION SYSTEM Oil Pump Relief Valve Oil Pump Relief Valve Inspection e Remove the oil pump see Oil Pump Relief Valve Re moval e Visually inspect the pump gear outer and inner rotor and cover plate x If there is any damage or uneven wear replace them with new ones OCheck the clearance
87. nder with 400 emery cloth or light honing x lf the damage is severe replace the crankcase and pis tons Piston Cleaning e Remove the piston and the 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 material will not damage the piston head KEO6088BS2 C KEO6089BS1 o Cylinder Piston ENGINE TOP END 5 19 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 with new ones x lf the ring grooves are worn unevenly or damaged re place both the piston and the piston rings with new ones 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 as shown x If the piston ring groove clearance is greater t
88. ner 1 550 r min rpm 3 600 r min rpm Heavy duty type Primary element Secondary element Engine Top End Valve Clearance Inlet Exhaust Valve Seating Surface Angle Inlet Exhaust Valve Seating Surface Width Exhaust Inlet Lubrication System Engine Oil Type Viscosity Capacity Level Electrical System Spark Plug Spark Plug Gap 0 10 0 15 mm 0 0039 0 0059 in 45 1 0 1 5 mm 0 039 0 059 in 0 7 1 1 mm 0 028 0 043 in SF SG SH SJ or SL class SAE 40 SAE 30 SAE 10W 30 SAE 10W 40 or SAE 5W 20 1 7 L 1 8 US qt When the oil filter is not removed 1 9 L 2 0 US qt When the oil filter is removed Operating range grid area on dipstick NGK BPRSES 0 7 0 8 mm 0 028 0 031 in 1 Idle speeds may vary depending on each equipment Refer to the equipment specification 2 6 PERIODIC MAINTENANCE Special Tools Valve Seat Cutter 45 p27 5 57001 1114 ST5711148T Valve Seat Cutter 45 635 57001 1116 ST5711168T Valve Seat Cutter 32 630 57001 1120 ST571120ST Valve Seat Cutter 32 635 57001 1121 ST5711218T Valve Seat Cutter Holder 7 57001 1126 8757112697 Valve Seat Cutter Holder Bar 57001 1128 Oil Filter Wrench 57001 1249 Valve Seat Cutter Holder 66 57001 1360 ST5711288ST T5712498T ST571360ST PERIODIC MAINTENA
89. ning and In Spark Plug Gap Inspection DEEG eh ee NT 2 2 2 3 2 5 2 6 2 7 2 7 2 7 2 7 2 8 2 9 2 9 2 9 2 10 2 10 2 11 2 11 2 14 2 14 2 14 2 15 2 16 2 16 2 16 2 16 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 OPERATION Every 250 Every Every 300 500 hr hr hr Check and clean air inlet screen Check and add engine oil Check for fuel and oil leakage e Check for loose or lost nuts and screws Check battery electrolyte level e Replace air cleaner primary element 1 Check air cleaner secondary element 1 Replace air cleaner secondary element 1 Clean cylinder and cylinder head fins 1 Tighten nut and screws Change engine oil Clean and re gap spark plugs Check and clean oil cooler fins Change oil filter Check and adjust valve clearance Clean and lap valve seating surface Clean combustion chambers 1 Service more frequently under dusty
90. oint solvent to clean the cylinder head A fire or explosion could result 2 10 PERIODIC MAINTENANCE Periodic Maintenance Procedures Valve Clearance Inspection NOTE OCheck the valve clearance when the engine is cold at room temperature e Remove the rocker cover see Cylinder Head Assembly Removal in the Engine Top End chapter e Place the piston at the top dead center TDC of the com pression stroke by turning the crankshaft clockwise facing the flywheel No 1 Cylinder OThe left projection A on the flywheel is faced with the right leg B on the 1 ignition coil C as shown in the figure OCheck the inlet and exhaust valves are closed completely if they are not closed turn the flywheel one turn 360 clockwise and face the left projection with the right leg again No 2 Cylinder OThe left projection A on the flywheel is faced with the right leg B on the 2 ignition coil C as shown in the figure Follow No 1 Cylinder alignment e Check the valve clearance OUsing a thickness gauge A measure the valve clearance between the rocker arm B and the valve stem end x lf the valve clearance is no correct adjust it Valve Clearance when cold Inlet Exhaust 0 10 0 15 mm 0 0039 0 0059 in Valve Clearance Adjustment e Since valve repairs change the valve clearance adjust the valve clearance as specified e Assemble the cylinder head and install the cylinder head assembly on the b
91. otating parts of engine and equipment during test CAUTION If starter does not stop by engine switch OFF dis connect negative cable from battery as soon as possible STARTER DOES NOT ROTATE e Faulty battery Charge or replace e Faulty leads or connection Repair or replace e Melted fuse Replace e Faulty engine switch Repair or replace e Faulty solenoid switch Replace Is there click sound from solenoid switch e Weak battery Charge or replace e Faulty leads or connection Repair or replace Solenoid to motor e Faulty solenoid switch Replace e Main terminal in solenoid e Faulty starter motor Repair or replace STARTER ROTATES BUT SLOW Is battery normal and well NO gt e Weak battery Charge or replace charged YES e Faulty leads or connection Repair or replace Solenoid to motor e Faulty solenoid switch Replace e Main terminal in solenoid e Faulty starter motor Repair or replace e Faulty engine Repair or replace STARTER ROTATES BUT CAN NOT CRANK ENGINE Does pinion mesh with ring NO e Worn pinion or ring gear Replace gear e Wrong starter alignment Correct YES e Faulty pinion clutch Replace e Faulty engine Repair or replace STARTER DOES NOT STOP IN ENGINE SWITCH OFF Can stop starter by engine NO e Faulty engine switch Repair or replace switch OFF e Faulty solenoid switch Replace YES e Faulty pinion or
92. ough the crankcase Then it is led to the air cleaner Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase and then returned back to the bottom of crankcase 2 Exhaust Emission Control System The exhaust emission control system applied to this engine consists of a carburetor and an ignition system having optimum ignition timing characteristics The carburetor has been calibrated to provide lean air fuel mixture characteristics and 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 par
93. r selector switch to the R x 1 O position and connect the leads 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 If 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 Electric Starter System STARTER SYSTEM 8 7 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
94. ram Yellow Red mmm hu 6B020601w1 18 Replacement Parts When there is a replacement instruction replace these parts with new ones every time they are removed There replacement parts will be damaged or lose their original function once removed 19 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure 20 Specifications Specification terms are defined as follows Standards show dimensions or performances which brand new parts or systems have Service 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 FX921V FX1000V oe 1 6B03007BwWw9 C No 1 Cylinder is the left hand cylinder viewed from the air cleaner No 2 Cylinder is the right hand cylinder viewed from the air cleaner Cylinder Number Designation General Specifications GENERAL INFORMATION 1 5 FX921V FX1000V Type Forced air cooled vertical shaft OHV 6 valves 4 stroke gasoline engine Cylinder Layout 90 V Twin Bore x Stroke Displacement 89 15 mm x 80 mm 3 5 in x 3 15 in 999 cm 6
95. ring gear Repair or replace e Wrong starter alignment Correct e Faulty pinion return mechanism Repair or replace KI03009B_F BE amp Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 2082 01 Printed in Japan
96. rong valve timing e Broken valve spring e Stuck valve e Plugged oil ring groove e High oil level eWorn valve stems and valve guide e Oil leakage along governor shaft e Oil leakage from oil seal e Oil leakage from mounting surface e Qil leakage from drain plug e Clogged breather valve e Drain back hole in breather chamber plugged e Incorrect oil viscosity eWorn piston rings e Stuck piston rings e Worn cylinder bore e Broken piston ring e Loose carb or inlet manifold e Loose cyl head or leaking head gasket e Burned or sticking inlet valve e Faulty ignition coil e Carb not properly adjusted e Stale fuel e Excessive carbon deposit in engine e Excessive engine load e Engine overheating e Faulty ignition coil Adjust Adjust Open choke Adjust Replace Clean or replace Replace Retighten Lap Adjust valve clearance Adjust Replace Clean or replace Clean Adjust Replace Replace Replace Replace gasket Retighten or replace gasket Clean Clean Correct Replace Clean or replace Replace Replace Tighten Tighten Replace Replace Adjust Change Clean Adjust See engine loss power Replace K102064B F 10 6 TROUBLESHOOTING Starter Motor Troubleshooting Guide 1 Disconnect the spark plug caps from the spark plugs 2 Turn engine switch to start position and check condi tion 44 WARNING Engine may be cranked in this test Do not touch any r
97. ry element A every 250 hrs PERIODIC MAINTENANCE 2 9 Periodic Maintenance Procedures e Replace the secondary element A with a 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 Air Cleaner Housing Cap and Body Inspection e Remove Element see Element Removal in the Fuel System chapter Air Cleaner Housing see Air Cleaner Body and Bracket Removal in the Fuel System chapter e Clean the housing with detergent and water and dry the housing thoroughly e Check the housing for deformation or other damage OSeal the housing well and permit only filtered air to reach the carburetor x If the housing is damaged replace the housing with a new one e Check that no foreign material obstructs the air passage Engine Top End Cylinder Head Cleaning e Scrape the carbon deposits from the cylinder head and the exhaust port with a suitable tool A e To avoid gouging use scrapers that material will not dam age the cylinder head e Clean the head in a bath of high flash point solvent and dry it with compressed air 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 p
98. s x If the resistance is not as specified replace the regulator with a new one ELECTRICAL SYSTEM 9 13 Ignition System This engine ignition is controlled by a solid state ignition assembly and requires no periodic main tenance except for the spark plugs The system consists of the following Inductive Ignition Assemblies Permanent Magnet Flywheel Spark Plugs Stop Switch D 1 SW KHO7002BW2 B Base M Magnet C Collector N North Pole Co Core Lamination R1 Control Resistor D1 Diode S South Pole E Emitter SP Spark Plug F Flywheel SW Stop Switch L1 Primary Coil TS1 Trigger Sensor L2 Secondary Coil Q1 Transistor Ignition Theory of Operation Mounted to the periphery of a flywheel are a pair of magnetic poles south leading in clockwise rotation generated by a permanent magnet By rotating the flywheel magnetic poles clockwise past the ignition module on a laminated core group a voltage is generated in the primary winding L1 This generates a small bias current to flow through the control resistor R1 to the base B of Tran sistor Q1 This base drive causes the transistor to conduct turns on completing the primary circuit Current flows from the high side of the primary winding through the transistor collector C to emitter E to ground The trigger sensor TS1 senses the optimum time peak current to remove the base drive from the transistor This abrupt turning off
99. s A sealed type crankcase emis sion control system is used to eliminate blow by gases The blow by gases are led to the breather chamber through the crankcase and the camshaft Then it is drawn into the clean side of the air cleaner through the cylinder head and the hose and mixed with the clean air flow and subsequently coming into the combustion chamber through the carburetor and the inlet manifold The oil is primarily separated from the gases while passing through the inside of the rocker chamber from the crankcase and secondly separated from the gases in the breather chamber then returned back to the crankcase cover qm oi gt Fresh Air SL ZA Blow by Gas d Y ERNS hi E ES TZ EE HLZ cn AC D TT e Le i Ui Lal es EE ES ES Ez z KG08028BW4 C 7 12 CAMSHAFT CRANKSHAFT Breather Breather Valve Removal e Remove Inlet Manifold see Inlet Manifold Removal in the Fuel System chapter Bolts A Breather Chamber Cover B e Remove Screws A Breather Valve B Breather Valve Installation e Install the breather valve e Tighten Torque Breather Valve Mounting Screws 2 0 N m 0 20 kgf m 18 in Ib e Be sure the drain holes A on the breather chamber does not accumulate with slugs e Replace the breather chamber cover gasket with a new one e Tighten Torque Breather Chamber Cover Bolts 5 9 N m 0 60 kgf m 52 in Ib
100. sembly If a part seems especially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removal of screws held by a locking agent in order to avoid damaging the heads 6 Edges Watch for sharp edges especially during major engine disassembly and assembly Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over 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 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 material and perfectly smooth to avoid oil or compression leaks 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 inn
101. sun M UE A A datur ates uu near Onan aitaa 7 6 Crankcase Cover Installation cccccccccecccecccecccceeececeeeeceeeeeeeeeeeeeseeeeeeeeeeeeeeeeeeeeeeeeeeetess 7 7 Crankcase Assembly at rl Eege 7 8 Crankcase Inspection sisi 7 9 Crankcase and Crankcase Cover Cleaning 7 10 EI LUE RE A A D TE ONE OS 7 11 Breather Valve Removal iii 7 12 Breather Valve Installation EEEn EEEn EEEn EEEa 7 12 Breather Valve Inspection ooocccncccnncnnncnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnneninnnss 7 12 Breather Pipe Removal sis 7 13 Breather Pipe Installation 7 13 Camshaft Jager isa genee 7 14 Camshaft Tappet Removal 7 14 Camshaft Tappet Installation ss 7 14 Camshaft Disassembly E 7 15 Ee TEE 7 15 Camshaft Inspection cional da ea 7 15 Camshaft Bearing Journal Wear tes these Add 7 15 Crankshaft Connecting Rod oococccccccccccccccoccnnccconononnnnnonnncnnn nn r ren 7 17 ele Le Re Bn EE 7 17 Connecting Rod Installati n rissin EH 7 17 Crankshaft Removal ecoococioi ias A suite N 7 17 Crankshaft N Stala OTi e e aeaa a aae aa aa a aaa a ea aaea aa aaa 7 17 Cleaning Inspection zeit a a EENS dienaas 7 17 Connecting Rod Bend RK EE 7 18 Connecting Rod Big End Crankpin Width Wear 7 18 Connecting Rod Big End Bearing Crankp
102. t 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 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 contact on the valve seat with the 45 cutter to remove any possible burrs at the edge of the seat e After resurfacing the seat inspect for even valve seating 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 x If the seat does not make proper contact lap the va
103. the battery condition NOTE OAlways check the battery condition before judging other parts of the charging system The battery must be fully charged for 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 xlf the output voltage dose not rise as the engine speed increase the regulator is defective or the alternator output is insufficient for the loads Regulated Output Voltage Battery Voltage to 15 V DC Omg P Charging System ELECTRICAL SYSTEM 9 11 Stator Coil Resistance e Disconnect the connector A e Measure the stator coil resistance Electric Starter Model OComnect an ohmmeter between stator pins B Stator Coil Resistance 0 01 to 0 1 Q If the measured value is not within the specification re place the stator coil with a new one x If the coil has normal resistance but the voltage inspec tion shows the alternator to be defective the flywheel magnets have probably weakened and the flywheel must b
104. the number of turns until it seats fully but not tightly and then remove the screw This is to set the screw to its original position when as sembling OTurn in the new pilot screw fully but not tightly and then back it out the same number of turns counted during dis assembly Olnstall a new pilot screw plug in the pilot screw hole by pressing with the rod C and apply a small amount of a bonding agent D to the circumference of the plug to fix the plug e When assemble the carburetor note the following OApply engine oil SAE30 equivalent to the seals of the choke and throttle shaft Olnstall the choke valve and throttle valve on the shaft as the out side mark of them facing out side and apply a small amount of a bonding agent to the valve screw threads CAUTION Do not apply too much bonding agent to the valve screws itself or they may be fixed OFit the stopper of the carburetor body into the hole in the spacer OAssemble the carburetor parts with recommended tight ening torque see Exploded View KCO5108BS1 o Carburetor FUEL SYSTEM 3 15 Carburetor Cleaning 44 WARNING Clean the carburetor in a well ventilated area and take care that there is no sparks or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean the carburetors CAUTION Do
105. ts e Inlet pipe and tube Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic 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 Rem
106. ure 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 with a new one Pump Shaft Outside Diameter Service Limit 10 923 mm 0 43004 in e Measure the inside diameter A of the pump shaft bear ing in the crankcase with an inside micrometer at several points x lf the inside diameter is more than the service limit re place the crankcase with a new one Pump Shaft Bearing Inside Diameter Service Limit 11 068 mm 0 43575 in e Visually inspect the relief valve spring steel ball and valve seat in the crankcase If any rough spot is found during above inspection wash the valve clean with a high flash point solvent and blow out any foreign particles on 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 lf cleaning does not solve the problem replace the relief valve parts with new ones x If necessary put the ball in position and lightly tap the ball with a suitable tool to form a perfect seat e Measure the 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 with a new one Relief Valve Spring Free Length Service Li
107. w the flange surface E as shown e Do not damage the seal lips F 0 1 mm 0 0 04 in G Flywheel Side e When replacing the oil seal A of the governor shaft note the following Olnstall the oil seal into the crankcase cover B after in serted the governor shaft C in the crankcase cover and so that the marks D face out OThe depth E is 1 mm 0 04 in e Install the governor shaft and plate see Governor Shaft Installation in the Fuel System chapter Crankcase Cover Installation e Install the following parts into the crankcase Oil Pump and Relief Valve see Oil Pump Relief Valve Installation in the Lubrication System chapter Crankshaft see Crankshaft Installation Tappets and Camshaft see Camshaft Tappet Installa tion Breather Pipes and Cover e Apply liquid gasket A to the mating surface of the crankcase cover Sealant Kawasaki Bond 92104 1063 NOTE OMake the application finish within 30 minutes when the liquid gasket to the mating surface of the crankcase cover is applied OMoreover fit the case and tighten the cover bolts just after finishing the application of the liquid gasket KG04062BS1 o 7 8 CAMSHAFT CRANKSHAFT Crankcase e Check to see that the dowel pins A are in place on the crankcase e Install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence as shown Torque Crankcase Cover Bolts 46 N m 4 7 kgf
108. wn so that the tappets will fall away from the cam lobes e Remove the spacer A e Pull the camshaft B out of the crankcase e Remove the tappets A and mark them to reinstall in their original positions during assembly Camshaft Tappet Installation e Apply engine oil to the followings Tappet Journal Camshaft Journal Crankcase Side Cam Lobe Surface Camshaft Gear Camshaft Bearing e Apply molybdenum disulfide oil solution to the crankcase cover side of the camshaft journal OThe molybdenum disulfide oil solution is a mixture of en gine oil and molybdenum disulfide grease with a weight ratio 10 1 e Align the punch marks A on the crankshaft gear and camshaft gear CAMSHAFT CRANKSHAFT 7 15 Camshaft Tappet e Install the spacer A on the camshaft Camshaft Disassembly e Remove Governor Assembly see Governor Assembly Removal in the Fuel System chapter Spring A ODo not remove the ACR automatic compression release weight B Camshaft Assembly e Install the governor assembly see Governor Assembly Installation in the Fuel System chapter e After assembling the camshaft check the following items OThe governor plate A must move freely OWhile shaking the camshaft check if the ACR weight B swings smoothly Camshaft Inspection e Check the camshaft gear A for pitting fatigue cracks burrs or any evidence of improper tooth contact Replace the camshaft with a new one if
109. work Especially note the following 1 Dirt Before removal and disassembly clean the engine Any dirt entering the engine carburetor or other parts will work as an abrasive and shorten the life of engine For the same reason before installing a new part clean off any dust or metal filings 2 Battery Ground Remove the ground lead from the battery before performing any disassembly operations on the equipment This prevents a the possibility of accidentally turning the engine over while partially disassembled b sparks at electrical connections which will occur when they are disconnected c damage to electrical parts 3 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 disas

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