Service Manual
Contents
1. seceeceeeseseeeeeeeeseeeeeeeeeeeeeeeeeeeseeeseeeeaeseaeceeeseeeseaeenaeseaeeeaeseaeseneenaeeaas 2 10 Engine Assembly Installation comal a tad 2 10 Engine Italic oca 2 10 Throttle Cable Free Play AdjUstme rit iiciin inian ida idos 2 11 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 2 KHD600A Disassembly Procedure Cutter blades can cause severe injury Wear gloves to protect the hands when handling the cutter blades Perform a disassembly operation only after stopping the engine and draining the gasoline from the fuel tank Exercise extreme caution to prevent burns or fire Engine Assembly Removal e Remove the air filter cap and remove the cable from the carburetor arm A e Also remove the positive lead for the switch from the terminal e Then remove the three Allen bolts D from the gear case B and the bracket C and detach the engine from the body Handle Assembly Removal e Remove the two nuts and two Allen bolts A from the handle assembly to remove the handle assembly from the gear case and the complete cutter Gear Case and Cutter Removal e Remove the two M5 nuts from the plate B of the upper gear case A e Remove the four M6 nuts C for the cutter adjustment screws to detach the plate B and the blade guard D from the body lt _ E E ieee oy z f PU MT L EE www mymowerparts com For2. 5 0 N m 0 4 0 5 kg m e Place the upper cutter A and the lower cutter B together Insert one L 22 mm screw with washer C into the hole through both cutters at the gear case side and the three L 19 mm screws D at the cutter end and lightly tighten them against the plate e Next back off the screws 1 4 to 1 2 turns to adjust the cutter clearance Blade clearance 0 3 0 4 mm Cutter Adjustment Screw Installation and Clearance Adjustment ye www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 KHD600A 2 7 Reassembly Procedure Cutter Adjustment Screw Tightening e Place the blade guard B on the plate A Use the driver C to support the four screws of the plate A Then tighten the four M6 nuts to the specified torque Place the plate over the single bolt on the gear case side and tighten it together N Torque 11 14 N m 1 1 1 4 kg m End di NOTE WTA AA After tightening the screws make sure that the cutter moves O smoothly Plate Installation e Tighten the two M5 nuts C to the specified torque to install the plate B on the upper gear case A Torque 4 0 5 0 N m 0 4 0 5 kg m A AWARNING j pod Before tightening the nuts on the plate make sure to install the cutter guard D www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 8 KHD600A Reassembly Procedure Handle Asse
3. B Gear Holder 57001 1424 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 4 KHD600A Reassembly Procedure Gear Case and Cutter Installation Procedure Exploded View 1 Clutch Drum 8 Lower Gear Case 2 Reinfor Plate Nuts 9 Pinion Gear 3 Locknuts 10 Upper Gear Case 4 Cutter Blade Guide Screws 11 Cam Gear 5 Guide Plate Mounting Screws 12 Con Rods with Needle Rollers 6 Cutter Blade Guide Plate 13 Upper Cutter Blade Short 7 Gear Case Bolts 14 Lower Cutter Blade Long www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 KHD600A 2 5 Reassembly Procedure Bearing and Nipple Installation on Upper Case e On the upper gear case A press fit the ball bearings 6001RS B and 608ZL C and install the grease nipple NOTE The stamped side of the ball bearing must be visible Clutch Drum Installation e Insert the threaded side of the gear A into the ball bearing 6001RS and tighten the clutch drum B from above At this time apply a non permanent locking agent on the threads of the clutch drum B NOTE Use two types of special tools to tighten the clutch drum Special Tools Socket Wrench 57001 1418 A Gear Holder 57001 1424 B CAUTION The socket wrench special tool must be used by ensuring that its two protrusions engage completely with the clutch drum The gear holder
4. GENERAL INFORMATION 1 7 Periodic Maintenance Chrat AWARNING Accidental engine starting can cause injury Always remove the spark plug cap before serving the engine to prevent accidental starting Maintenance ENGINE Check and replenish fuel Check for fuel leakage Check bolts screws nuts for looseness and loss Check throttle lever operation Check engine switch operation Clean fuel filter Clean air filter element Tighten bolts screws and nuts Clean spark plug and adjust electrode gap Remove dust and dirt from cylinder fins Remove carbon deposits on piston head and inside cylinder Remove carbon deposits in the exhaust pipe of muffler Clean net of spark arrester Check the sliding portion of crankshaft connecting rod etc Fuel tube Replace every 3 years CUTTER BLADES MAIN BODY Check bolts screws nuts for looseness and loss Clean cutter blades and each component Apply oil to cutter blades e Apply grease to gear case e Tighten mounting bolts of cutter blades e NOTE o The service intervals indicated above are to be used only as guide All items should be performed more frequently if the engine is subjected to severe operating conditions www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 1 8 GENERAL INFORMATION Tightening Torque The following tables list the tightening
5. Install the front handle assembly A on the rear handle assembly B and tighten the two Allen bolts and nuts to the specified torque Torque 6 0 8 0 N m 0 6 0 8 kg m Damper and Collar Installation and Bracket Installation e Insert the four upper and lower dampers B and the two collars C into the front gear case mounting area A of the rear handle assembly e Then insert the four upper and lower dampers D and the two collars E into the rear mounting area and tighten the Allen bolts to the bracket F at the specified torque e Also install the dampers and collars to the center of the bracket F Torque 6 0 8 0 N m 0 6 0 8 kg m NOTE Install the bracket F with its protruded portion facing rearward www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 10 KHD600A Reassembly Procedure Handle Assembly Installation on Gear Case e Starting with the blade B pass the gear case A through the center hole of the handle assembly to install it on the handle assembly e Place the washers on the upper dampers of the front mounting area and tighten them with the two Allen bolts and nuts C to the specified torque Torque 6 0 8 0 N m 0 6 0 8 kg m Engine Assembly Installation e Cable installation and adjustment O Connect the handle assembly cable to the carburetor of the engine then install the engine on the complete case A O After inst
6. rod ee must be replaced as an assembly e Remove the clutch drum e Place the special tools against the clutch drum and the gear Use a hammer to lightly tap counterclockwise on the special tool that is placed against the clutch drum thus removing the drum Refer to the section for KHD600A www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 4 KHS750A Reassembly Procedure Gear Case and Cutter Installation Procedure Exploded View 1 Clutch Drum 7 Con Rods with Needle Rollers 13 Guide Plate 2 Reinfor Plate Nuts 8 Guard 14 Gear Case Bolts 3 Locknuts 9 Cutter Blade Guide Screws 15 Felt Seal 4 Reinforce Plate 10 Lower Cutter Blade Long 16 Lower Gear Case 5 Upper Gear Case 11 Upper Cutter Blade Short 17 Pinion Gear 6 Cam Gear 12 Guide Plate Mounting Screws 18 Rear Handle Mounting Bolts 19 Front Handle Mounting Bolt www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 KHS750A 3 5 Reassembly Procedure Bearing and Nipple Installation on Upper Case e On the upper gear case A press fit the ball bearings 6001RS B and 608ZL C and install the grease nipple NOTE The stamped side of the ball bearing must be visible Clutch Drum Installation e Insert the threaded side of the gear A into the ball bearing 6001RS or and tighten the clutch drum B from above At this time apply a Emy non pe
7. s7 i a J i J an ZAS y bN Rear Handle Assembly Installation e Install the following parts onto the left body A O Tighten the switch B using two 3 x 10 screws O Install the throttle lever C with the throttle cable D fitted At the same time fit the return spring in the throttle lever to enable the lever s return operation O Install the stop lever E At the same time enable the spring s return g y e operation He i NOTE Fit the outer and inner tips of the throttle cable to the specified B L locations CAUTION Route the switch lead wires so as not to cause an open or short circuit as this could prevent the engine from starting or stopping Fit the lead wire into the lead guide insert it into the tube and pull it out together with the throttle cable O Mate the right body with the left body and tighten them with the three screws Front Handle Installation e Refer to the previous section on Cutter Adjustment Screw Tighten ing www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 10 KHS750A Reassembly Procedure Rear Handle Mounting Bracket Installation e Insert the damper A and the collar B into the damper hole and via the plate C tighten the bolt D to the specified torquie al D Torque 4 5 5 0 N m 0 4 0 5 kg m Engine Assembly Installation Cable Installation and Adjustment e Connect the handle assem
8. special tool must make full contact with the gear Plate Installation e Install the plate B on the upper gear case A and tighten the two 5 x 20 screws C to the specified torque Torque 4 0 5 0 N m 0 4 0 5 kg m www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 6 KHD600A Reassembly Procedure Cutter and Rod Installation e Insert the gear B into the ball bearing 608ZL of the upper gear case A Then on the cam C of the gear B install in sequence the cutter rods on which the upper cutter D and the lower cutter E are fitted e After the installation apply grease to the gear and the cutter rods NOTE 1 Apply approximately 50g of grease 2 Use the special tool for installing the snap ring 3 Orient the rod so that the recessed side of the rod faces inward Special Tool Circlip Pliers 57001 154 AWARNING Cutter blades can cause severe injury Wear gloves to protect the hands when handling the cutter blades Bearing Installation on Lower Case e On the lower gear case A press fit the ball bearing 608ZL B and tighten the two 3 x 5 screws to install the rod plate C e Then install the seal E in the upper gear case D Upper and Lower Case Installation e Tighten the five 5 x 16 bolts C and the two 5 x 16 bolts D to the specified torque to install the lower gear case A on the upper gear case B Torque 4 0
9. For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 Kawasaki Hedge Trimmer Chapter of cutter blades main body Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Department Consumer Products amp Machinery Group Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts O Kawasaki Heavy Industries Ltd 1999 First Edition Jan 29 1999 K www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LIST OF ABBREVIATIONS A ampere s ABDC after bottom dead center AC alternating current ATDC after top dead center BBDC before bottom dead center BDC bottom dead center BTDC before top dead cen
10. HS750A M5 11214 1 10 1 40 8 1 10 Front Handle MTGS KHD600A M6 6 0 8 0 0 60 0 80 53 71 in lb Front Handle MTGS KHS750A M6 6 0 8 0 0 60 0 80 53 71 in lb LA Rear Handle MTGS KHD600A M6 6 0 8 0 0 60 0 80 53 71 in lb Rear Handle Bracket Lower KHS750A M6 6 0 8 0 0 60 0 80 53 71 in lb Rear Handle Bracket Upper KHS750A M5 35 40 0 35 0 40 31 35 in lb Engine MTGS KHD600A KHS750A M6 6 0 8 0 0 60 0 80 53 71 in lb www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 9 Special Tools Sealant Outside Circlip Pliers 57001 144 Holder amp Puller 57001 1418 A SS 5 fe E Gear Holder 57001 1424 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 1 10 GENERAL INFORMATION Sharpening Cutter Edges Preparation e Prepare the following tools to sharpen the cutter edges Air powered disc grinder NOTE A battery powered grinder may not have enough disc speed When disc speed is slow the cutter edges will be annealed Grinder Disc of about 100 mm Diameter and 2 mm Thick 60 Grain for Steel Grinding Vice Grips or Small Clamp Screw Driver Wrench for 10 mm Hexagon Nut Wood Blocks Cutter Edges Sharpening 1 To sharpen Front and Rear Edges e Slide the upper and lower cutter blades so that the edges to be sharpened are about 2 3 mm from each other A Grinder Disc B U
11. Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 KHD600A 2 3 Disassembly Procedure AWARNING Cutter blades can cause severe injury Wear gloves to protect B the hands when handling the cutter blades e Remove the cutter guard A and remove one L 22 mm cutter NGN ee alect pn mounting screw B from the gear case and the three L 19 mm mounting screws C from the tip together with the nuts AWARNING After removing the screws make sure to install the cutter guard to prevent injury from the cutter blades e Remove the five 5 x 16 bolts B and the two 5 x 16 bolts C from the lower gear case A to remove the lower gear case A from the upper gear case D e Remove the seal E and the cutter rod F to remove the cutter guard then remove the upper and lower cutters e Using the special tool remove the snap ring to remove the cutter rod G Special Tool Circlip Pliers 57001 154 e Then remove the large and small gears from the upper gear case NOTE The cutter rod contains 30 rollers Make sure not to lose them during disassembly If any roller has been lost the cutter rod must be replaced as an assembly e Remove the clutch drum A e Place the special tools against the clutch drum and the gear Use a hammer to lightly tap counterclockwise on the special tool that is placed against the clutch drum thus removing the drum Special Tools Socket Wrench 57001 1418
12. alling the engine route the cable through the inside of the tank O After assembling the engine adjust the cable play to enable the carburetor throttle to effect idling and wide open throttle through the operation of the throttle lever of the handle assembly After the adjustment tighten the lock nut and verify that the throttle lever of the handle assembly operates smoothly Engine Installation e Tighten the two 6 x 16 Allen bolts A and one 6 x 40 Allen bolt B to the speified torque e Tighten the ground terminal C together with the rear mounting area Torque 6 0 8 0 N m 0 6 0 8 kg m www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 KHD600A 2 11 Reassembly Procedure Throttle Cable Free Play Adjustment e After the throttle cable A has been connected to the carburetor place the throttle lever at its idle position Then adjust the free play of the throttle cable A to about 1 mm 0 04 in by turning the adjuster B with the loop handle installed in place e Tighten the lock nut C to prevent the adjuster B from loosening Free play www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 KHS750A 3 1 KHS750A Table of Contents Disassembly POCA UE a eee 3 2 Engine Assembly REMOVAL ai 3 2 Rear Handle Removal ina
13. ar Case and Cutter Removal e Remove the two M5 nuts from the plate B of the upper gear case A e Remove the four M6 nuts C for the cutter adjustment screws to detach the plate B and the blade guard D from the body Cutter blades can cause severe injury Wear gloves to protect the hands when handling the cutter blades www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 KHS750A 3 3 Disassembly Procedure e Remove the cutter guard A and the five screws and washers B that are used for mounting the cutter e Remove also the top guard C AWARNING After removing the screws make sure to install the cutter guard to prevent injury from the cutter blades e To remove the handle mounting bracket A remove the washers dampers and collars together with the two 5 x 35 bolts B e Remove the five 5 x 16 bolts D and the two 5 x 16 bolts E from the lower gear case C to remove the lower gear case C from the upper gear case e Remove the seal A and the cutter rod to remove the cutter guard then remove the upper B and lower C cutters e Using the special tool remove the snap ring to remove the cutter rod Refer to the section for KHD600A e Then remove the large and small gears from the upper gear case KE The cutter rod contains 30 rollers Make sure not to lose them during disassembly If any roller has been lost the cutter
14. bly cable to the carburetor of the engine then install the engine on the complete case A O After installing the engine route the cable through the inside of the tank O After assembling the engine adjust the cable play to enable the carburetor throttle to effect idling and wide open throttle the operation of the throttle lever of the handle assembly O After the adjustment tighten the lock nut and verify that the throttle lever of the handle assembly operates smoothly Engine Installation e Tighten the three 6 x 16 Allen bolts A to the specified torque e Tighten the ground terminal together with the rear mouonting area Torque 6 0 8 0 N m 0 6 0 8 kg m www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 KHS750A 3 11 Reassembly Procedure Throttle Cable Free Play Adjustment e After the throttle cable A has been connected to the carburetor place the throttle lever at its idle position Then adjust the free play of the throttle cable A to about 1 mm 0 04 in by turning the adjuster B with the loop handle installed in place e Tighten the lock nut C to prevent the adjuster B from loosening Free play www mymowerparts com
15. d be pressed into place using a suitable driver which contacts evenly with the side of seal until the face of the seal is even with the end of the hole 12 Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips Before a shaft passes through a seal apply a little oil preferably high temperature grease on the lips to reduce rubber to metal friction 13 Circlip Retaining Ring Replace any circlips and retaining rings that were removed with new ones as removal weakens and deforms them When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more 14 Cotter Pin Replace any cotter pins that were removed with new ones as removal deforms and breaks them www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 3 Before Servicing 15 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film During assembly oil or grease whichever is more suitable should be applied to any rubbing surface which has lost its lubricative film Old grease and dirty oil should be cleaned off Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles Don t use just any oil or grease Some oils and greases in particular should be used only in cer
16. dge of mechanics the proper use of tools and workshop procedures must be understood in order to carry out maintenance and repair satistacto rily Whenever the owner has insufficient experience or doubts his ability to do the work all adjustments mainte nance and repair should be carried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thoroughly familiarize yourself with the procedures before starting work and then do the work carefully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may adversely affect safe operation For the duration of the warranty period we rec ommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your equipment e Follow the Periodic Maintenance Chart in the Service Manual e Be alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki engine parts Special tools gauges and testers that are necessary when servicing Kawasaki vehicles are introduced by the Special Tool Catalog or Manual Genuine parts provided as spare parts are listed in the Parts Catal
17. is a aaa aa a 3 2 Front Handle Removal svcteccsccvcs aude dra dt dota eed 3 2 Gear Case and Gutter Removal mirren prii a A Phen 3 2 Reassembly Procedure mcr dale 3 4 Gear Case and Cutter Installation Procedure ooooonncccnonocaconononinonnnoncnonn nan nnon cnn nro r rene 3 4 Exploded Vi Witivi e ld don 3 4 Bearing and Nipple Installation on Upper CASO ooncocconnccncciccnncnonrncnrno nn corr nr cnn cnn rre 3 5 Clutch Drum Installation iaa 3 5 Plate Install OO A A i ed oe 3 5 Cutter and Rod Install vico id A di 3 6 Bearing Installation on Lower Case cecceeseeeceeseseeeeeeeneeeeeeeeeesaeeseeeeaeseeeseeeesaeseeeseeeesaeseeeseaeesaeseeeeeaeeeaeseaeeeaeeeaesenees 3 6 Upper and Lower Case Installation ceceecceeseeeeesceeeeeeeeeeeeeeeeeceeesaaeeseeseeseeeeseeesaeseaeseaeseaeseaeeeaeeeaeseaeseaeeeaeeeeeeateegs 3 6 Cutter Adjustment Screw Installation and Clearance AdjUStMent ccecceeceeeseeeeeeeeeeeeeeeeeeeeeeeeeeeeteeeteeesseeseneeneeeaaee 3 6 Cutter Adjustment Screw Tight ning c cessessesseeseesseeeseeeseecseeeaeeeseecaeesseesseecseesaeesseesseesseesaeesieeeseesseesieeseeeseeeeaeees 3 7 Plate Installations cosas tata dada dl 3 7 Handle Assembly Installation ProCeQure eeceeceesceseceeseeeneeeneeeeeeeeeeaeeeeeeseeseeeseesaeeeeesaeeeaeesaeeseeseeeeeseeseeeeesneeseees 3 8 Exploded VIEW sritan illa od td 3 8 Handle Assembly Installation sisirin aaea aca 3 9 Rear Handle Assembly Installati0N o
18. it the ball bearing 608ZL B and tighten the two 3 x 5 screws to install the rod plate C e Then install the seal E in the upper gear case D Upper and Lower Case Installation e Tighten the five 5 x 16 bolts C and the two 5 x 16 bolts D to the specified torque to install the lower gear case A on the upper gear case B Torque 4 0 5 0 N m 0 4 0 5 kg m Cutter Adjustment Screw Installation and Clearance Adjustment e Place the upper cutter A and the lower cutter B together Then from the gear case side insert the one L 29 mm screw A the two L 22 mm screws B and the two L 19 mm screws C through the cutter holes in the following sequence L 22 mm L 29 mm L 19 mm L 19 mm and L 22 mm and tighten them lightly against the plate e Tighten the L 22 mm screw at the tip together with the top guard e The screw at the tip tightened together with the top guard does not require a washer The remaining four screws require washers e Next back off the screws 1 4 to 1 2 turns to adjust the cutter clearance Blade clearance 0 3 0 4 mm www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 KHS750A 3 7 Reassembly Procedure Cutter Adjustment Screw Tightening e Place the blade guard B on the plate A Install the front handle C on the longest L 29 mm screw and tighten it with the 6 x 20 bolt to the specified torque e Then use the driver D
19. l filings 2 Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them evenly in a staggered sequence This is to avoid distortion of the part and or causing gas or oil leakage Conversely when loosening the bolts nuts or screws first loosen all of them by about a quarter of a turn and then remove them Where there is a tightening sequence indication in this Service Manual the bolts nuts or screws must be tightened in the order and method indicated 3 Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench 4 Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removal of screws held by a locking agent in order to avoid damaging the heads 5 Edges Watch for sharp edges especially during major engine disassembly and assembly Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over 6 High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A com
20. ll 606 678 9623 or 606 561 4983 1 6 GENERAL INFORMATION General Specifications Items KHD600A KHS750A Dimention Overall length Overall width Overall height Overall weight Engine Type Displacement Carburetor Stating method Blade activation prevention Ignition Spark plug Starter Clutch 1036 mm 40 8 in 244 mm 9 6 in 224 mm 8 8 in 5 7 kg 12 6 Ibs 1058 mm 41 6 in 292 mm 11 5 in 211 mm 8 3 in 5 5 kg 12 1 Ibs Forced air cooled 2 stroke vertical shaft gasoline engine 22 6 cm 1 38 cu in Diaphragm feed rotary valve side draft type walbro WYJ type Automatic return lift up Idle start Solid state ignition NGK BMR4A Recoil starter Automatic centrifugal type 454 mm 2 1 in Fuel Mixing ratio Tank capacity 50 parts of regular unleaded gasoline to 1 part of 2 stroke engine oil by volume 0 5L Blades Type Overall length Cuttin length Tooth pitch Speed Transmission Clutch type Gear ratio Drive Lubrication Double reciprocating single sided bladed 735 mm 28 9 in 692 mm 27 2 in 35 mm 1 38 in 986 mm 38 8 in sec 7000 rpm Double reciprocating double sided blades 598 mm 23 5 in 519 mm 20 3 in Dry type 1 4 14 14 T 58 T Two series camdrive Lithium grease Specifications are subject to change without notice and may not apply to every country www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983
21. mbly Installation Procedure Exploded View 1 Nut 7 Return Spring 12 Screw 2 Front Handle 8 Throttle Cable 13 Rear Handle Assembly 3 Damper 9 Spring 14 Bracket 4 Allen Bolt 10 Set Lever 15 Engine Switch 5 Collar 11 Rear Handle RH Half 16 Throttle Lever 6 Rear Handle LH Half www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 KHD600A 2 9 Reassembly Procedure Handle Assembly Installation The handle assembly consists of the rear A and front B portions Rear Handle Assembly Installation e Install the following parts onto the left body A O Tighten the switch B using two 3 x 10 screws O Install the throttle lever C with the throttle cable D fitted At the same time fit the return spring in the throttle lever to enable the lever s return operation O Install the stop lever E At the same time enable the spring s return operation NOTE Fit the outer tip of the throttle cable into the body receptacle and route the throttle cable outward through the inside of the case CAUTION Route the switch lead wires so as not to cause an open or short circuit as this could prevent the engine from starting or stopping Pull out the black white lead wire upward and the black lead wire downward O Mate the right body with the left body and tighten them with six 4 x 18 screws Front Handle Installation on Rear Handle Assembly e
22. mercial solvent commonly available in North America is Standard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent 7 Gasket O Ring Do not reuse a gasket or O ring once it has been in service The mating surfaces around the gasket should be free of foreign material and perfectly smooth to avoid oil or compression leaks 8 Liquid Gasket Non Permanent Locking Agent Follow manufacturer s directions for cleaning and preparing surfaces where these compounds will be used Apply sparingly Excessive amounts may block engine oil passages and cause serious damage An example of a non permanent locking agent commonly available in North America is Loctite Lock n Seal Blue 9 Press A part installed using a press or driver such as a journal should first be coated with oil on its outer or inner circumference so that it will go into place smoothly 10 Ball Bearing When installing a ball bearing the bearing race which is affected by friction should be pushed by a suitable driver This prevents severe stress on the balls and races and prevents races and balls from being dented Press a ball bearing until it stops at the stop in the hole or on the shaft 11 Oil Seal Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally damages seals When pressing in a seal which has manufacturer s marks press it in with the marks facing out Seals shoul
23. nocccnccocaconononanonanonnnono nan nnon nro rnn cnn rre rn 2 4 Exploded MiW iii o its 2 4 Bearing and Nipple Installation on Upper Case eecssceseceeseeeseeeeeeeeeeeneeeneeseeseeseeeaeesneeeaeesneesneeeeeeeesneeseeeeneeeaeees 2 5 Clutch Drum Installation sesers and oh ees ire ieee Se ne es ee ee ede 2 5 Plate Installati N lt seus ea ac 2 5 C tter and Rod Instalation y siiin iii 2 6 Bearing Installation on Lower Case ooooniccnccnnnnnncnnnnnncnncn cnn 2 6 Upper and Lower Case Installation cceceeceseceeeeeeceeeeeeeeeeeeeeeeeseeseeeeeesaeseeeeseessaeseaeseaeseaeseaeesaeseaeseaeeeaeeeaeeeeeeaeeags 2 6 Cutter Adjustment Screw Installation and Clearance AdjuStMeNt oocccnnccnncninnnnnconcnnnconncnnrcn rc nr 2 6 Cutter Adjustment Screw Tight ning csceecesseeseeseeeseeeseeeseecseeeaeeeseecseesseesseecseesaceeseesseesaeecseesieesaeeceeesieeseeseeetaeees 2 7 Plate Instalati irta api daria 2 7 Handle Assembly Installation ProCedure ooconnocnnnininonnoncnnconcnnorcnrcnrn nr rr 2 8 Exploded AA A E da t 2 8 Handle Assembly Installation cionado ii 2 9 Rear Handle Assembly Installations i 0 acini el annie A ae 2 9 Front Handle Installation on Rear Handle ASSEMDIy eecceeceeeeeeeeeeeeeeeeeseeeeeeeeseeseeeeaeeeeseeeesaesseesneeseaeseeeseeeeeaeeaes 2 9 Damper and Collar Installation and Bracket Installation ee eeeeseeseeseeeneeeeeeeseeeneesaeeeseesaeesaeeseesaeesaeesseesneeeeneeaes 2 9 Handle Assembly Installation on Gear Case oo
24. og e Follow the procedures in this manual carefully Don t take shortcuts e Remember to keep complete records of maintenance and repair with dates and any new parts installed How to Use This Manual All information for a particular system from adjustment through disassembly and inspection is located in a single chapter The Quick Reference Guide shows you all of the products work 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 Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices This warning symbol identifies special instruc tions or procedures which if not correctly fol lowed could result in personal injury or loss of life CAUTION This caution symbol identifies special instruc tions or procedures which if not strictly ob served could result in damage to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of information NOTE This note symbol indicates points of particular in terest for more efficient and convenient operation e Indicates a procedural step or work to be done O Indicates a procedu
25. onnoonncnnnnonnnnnnnnnoonrnncnnrcnnrnnnrcn rra 3 9 Front Handle Installation Rear Handle Mounting Bracket InstallatiOM oonooionninnninnninnnnnonnconononccnnccnnoro nara n or n arrancar 3 10 Engine Assembly Installation r nsin die APE anotan tes 3 10 Engine Install AA AA a a T 3 10 Throttle Cable Free Play AdjUStMent ce eeeeseeseeeseeeeceneeeseeeaeeeaeeeaeeeaecsaeesaeeaeesaeeeaeeaeesaeeeseseaeecaeesseseaeeeaeeeaeseaeenaees 3 11 www mymowertrparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 2 KHS750A Disassembly Procedure Cutter blades can cause severe injury Wear gloves to protect the hands when handling the cutter blades Perform a disassembly operation only after stopping the engine and draining the gasoline from the fuel tank Exercise extreme caution to prevent burns or fire Engine Assembly Removal e Remove the air filter cap and remove the cable from the carburetor arm A e Also remove the positive lead for the switch from the terminal e Then remove the three Allen bolts C from the gear case B and detach the engine from the body Rear Handle Removal e Remove the two Allen bolts D from the rear handle and remove the rear handle from the gear case ta Front Handle Removal e Remove the one 6 x 20 bolt A and the one M6 nut B from the front handle and remove the front handle from the plate cutter 7 a A Ge
26. pper Blade C Lower Blade e Secure both cutter blades with the clamp e Put the cutter blades on the blocks Keep the cutter blades stable while grinding the edges e Wear eye protection glasses to protect your eyes e Position the grinder so that the grinder disc is parallel with the edges NOTE o Push the grinder forward to sharpen edges in order to get flat sharp edges If you pull in the grinder to sharpen the edges you will get round dull edges e After sharpening the edges clean the surface of the cutter blades and apply a few drops of machine oil 2 To Sharpen Side Edges e Slide the upper and lower cutter blades so that the upper edges and lower edges align alternately 1 Grinding Disc 2 Upper Blade 3 Lower Blade 4 Make Sharp corner e Position the grinder so that the grinder disc is parallel with the edges e Finish the edge corners until they are sharp e After sharpening the edges clean the surface of the cutter blades and apply a few drops of machine oil www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 KHD600A 2 1 KHD600A Table of Contents Disassembly Procedure toi 2 2 Engine Assembly Removals s c02 cin iit aw ence oi 2 2 Handle Assembly Removal irsini oan ei eai hteatae such tia en cesta a evatetacss ia a aA aaa anii 2 2 Gear Case and Gutter Removal econ 2 2 Reassembly Procedure ci ia a 2 4 Gear Case and Cutter Installation Procedure oooooo
27. ral sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE x Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub step it follows www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 1 General Information Table of Contents Belore Servicio 1 2 Model oleske n A A TEA TN 1 4 General Specifications a sre aa a p a E E a as A oy al le aa R 1 6 Periodic Maintenance Caratula edad 1 7 Tightening Torque td A R a a Na 1 8 Special Tools Scala ios is iaa 1 9 sharpening Cutter EdJOS vicodin A nods dicas 1 10 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 1 2 GENERAL INFORMATION Before Servicing Before starting to service the engine carefully read the applicable section to eliminate unnecessary work Photographs diagrams notes cautions warnings and detailed descriptions have been included wherever necessary Nevertheless even a detailed account has limitations a certain amount of basic knowledge is required for successful work Especially note the following 1 Dirt Before removal and disassembly clean the engine Any dirt entering the engine carburetor or other parts will work as an abrasive and shorten the life of engine For the same reason before installing a new part clean off any dust or meta
28. rmanent locking agent on the threads of the clutch drum B Alo NOTE Use two types of special tools to tighten the clutch drum Special Tools Socket Wrench 57001 1418 A Gear Holder 57001 1424 B CAUTION The socket wrench special tool must be used by ensuring that its two protrusions engage completely with the clutch drum The gear holder special tool must make full contact with the gear Plate Installation e nstall the plate B on the upper gear case A and tighten the two 5 x 20 screws C to the specified torque Torque 4 0 5 0 N m 0 4 0 5 kg m www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 6 KHS750A Reassembly Procedure Cutter and Rod Installation e Insert the gear B into the ball bearing 608ZL of the upper gear case A Then on the cam C of the gear B install in sequence the cutter rods on which the upper cutter D and the lower cutter E are fitted e After the installation apply grease to the gear and the cutter rods NOTE o Apply approximately 50g of grease Use the special tool for installing the snap ring Orient the rod so that the recessed side of the rod faces inward Special Tool Circlip Pliers 57001 154 Cutter blades can cause severe injury Wear gloves to protect the hands when handling the cutter blades Bearing Installation on Lower Case e On the lower gear case A press f
29. tain applications and may be harmful if used in an application for which they are not intended This manual makes reference to molybdenum disulfide grease MoSz in the assembly of certain engine parts Always check manufacturer recommendations before using such special lubricants 16 Replacement Parts When there is a replacement instruction replace these parts with new ones every time they are removed These replacement parts will be damaged or lose their original function once removed 17 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure 18 Specifications Specification terms are defined as follows Standards show dimensions or performances which brand new parts or systems have Service Limits indicate the usable limits If the measurement shows excessive wear or deteriorated performance replace the damaged parts www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 1 4 GENERAL INFORMATION Model Identification KHD600A www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 5 Model Identification KHS750A www mymowertrparts com For Kawasaki Discount Parts Ca
30. ted into any new engine for the purpose of emission control prior to its sale or deliverly to the ultimate purchaser or while it is in use or 2 the use of the engine after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to consituite tampering are the acts listed below Do not tamper with the original emission related part e Carburetor and internal parts e Spark plugs e Magneto or electronic ignition system e Fuel filter e Air cleaner elements www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 Foreword This KHD600A KHS750A Service Manual is designed to be used in conjunction with the TF22 2 stroke air cooled gasoline engine Service Manual P N 99924 2503 02 The maintenance and repair procedures de scribed in this manual are only those that are unique to the body of the KHD600A KHS750A Hedge Trimmer Most service operations for this model remain identical to those described in the engine Service Manual Complete and proper servicing of the KHD600A KHS750A blower therefore requires both this manual and the engine Ser vice Manual The engine Service Manual and this manual are de signed primarily for use by trained mechanics in a properly equipped shop However they contain enough detail and basic information to make them useful to the owner who desires to perform his own basic maintenance and repair work A basic knowle
31. ter C degree s Celsius DC direct current F farad s F degree s Fahrenheit ft foot feet g gram s h hour s L liter s lb m min N Pa PS psi di rpm TDC TIR pounds s meter s minute s newton s pascal s horsepower pound s per square inch revolution revolution s per minute top dead center total indicator reading volt s watt s ohm s Read OWNER S MANUAL before operating www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated exhaust emission control systems EM in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board 1 Exhaust Emission Control System The exhaust emission control system applied to this engine consists of a carburetor and an ignition system having optimum ignition timing characteristics The carburetor has been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system TAMPERING WITH NOISE 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 incorpora
32. to support the five screws of the plate A e Then tighten the five M6 nuts to the specified torque Place the plate over the single bolt on the gear case side and tighten it together Torque Tightening torque for five nuts 11 14 N m 1 1 1 4 kg m Tightening torque for one bolt 4 0 5 0 N m 0 4 0 5 kg m NOTE After tightening the screws make sure that the cutter moves smoothly NON Plate Installation e Tighten the two M5 nuts C to the specified torque to install the plate B on the upper gear case A Torque 4 0 5 0 N m 0 4 0 5 kg m CAUTION Before tightening the nuts on the plate make sure to install the cutter guard D www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 8 KHS750A Reassembly Procedure Handle Assembly Installation Procedure Exploded View 1 Rear Handle Assembly 8 Tube 15 Grip Body Half 2 Grip Assembly 9 Throttle Cable 16 Return Spring 3 Rear Handlebar 10 Engine Switch 17 Throttle Lever 4 Nut 11 Screw 18 Front Handle Assembly 5 Band 12 Grip Body Half 19 Grip 6 Allen Bolt 13 Stop Lever 20 Front Handlebar 7 Bracket 14 Spring www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 KHS750A 3 9 Reassembly Procedure Handle Assembly Installation The handle assembly consists of the rear A and front B portions
33. torque for the major fastners requiring use of a non permanent locking agent or liquid gasket Leters used in the Fastners and Remarks columns mean MTGS Mounting screw s LA Apply a non permanent locking agent to the threads Tightening Torque KHD600A KHS750A Fasteners Size Nm E ftlb Remarks ENGINE Engine Shroud MTGS M4 1 7 2 0 017 0 20 15 18 in lb LA Muffler Cover MTGS M4 1 7 2 0 0 17 0 20 15 18 in lb LA Ignition Coil MTGS M4 2 0 2 5 0 20 0 25 18 22 in lb LA Recoil Starter MTGS M4 1 7 2 0 0 17 0 20 15 18 in lb LA Crankcase MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb LA Cylinder MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb Carburetor Air Cleaner Case MTGS M5 35 40 0 35 0 40 31 35 in lb Insulator MTGS M5 35 40 0 35 0 40 31 35 in lb LA Muffler MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb LA Fuel Tank MTGS M5 3 5 4 0 0 35 0 40 31 35 in lb LA Clutch Pin M6 6 0 7 0 0 60 0 70 53 62 in lb LA Flywheel Nut M8 14 16 1 40 1 60 10 12 in lb Spark Plug M14 12 17 1 20 1 70 8 9 13 in lb General Bolts and Nuts M4 25 3 0 0 25 0 30 22 27 in lb General Bolts and Nuts M5 3 5 4 0 0 35 0 40 31 35 in lb General Bolts and Nuts M6 6 0 8 0 0 60 0 80 53 71 in lb CUTTER BLADES BODY Case Gear MTGS KHD600A KHS750A 4 0 5 0 0 40 0 50 35 44 in lb Plate MTGS KHD600A KHS750A M5 4 0 5 0 0 40 0 50 35 44 in lb LA Cutter Blade Nut KHD600A K
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