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Kawasaki FH641V Service Manual

1. 4 27 Muffler Exhaust Pipe 4 27 Muffler Exhaust Pipe lnstalatioNk 4 27 Inspection 4 27 4 2 ENGINE TOP END Exploded View 6 O i 10 RCO D p SS ENGINE TOP END 4 3 Exploded View FH451V FH500V FH531V T1 5 9 N m 0 60 kg m 52 in Ib T2 5 9 N m 0 60 kg m 52 in Ib 3 25 N m 2 6 19 5 ft lb 4 28 N m 2 8 kg m 20 ft Ib T5 22 N m 2 2 kg m 16 ft lb FH601V FH641V FH680V FH721V T1 21 N m 2 1 15 ftlb T2 5 9 N m 0 60 52 in Ib 3 25 N m 2 6 kg m 19 5 ft lb 4 28 2 8 kg m 20 ft Ib T5 22 N m 2 25 kg m 16 ft lb O Apply engine oil G Apply grease S Follow the specific tightening sequence 4 4 ENGINE TOP END Exploded View ENGINE TOP END 4 5 Exploded View FH451V FH500V FH531V T2 15 N m 1 5 kg m 11 0 10 FH601V FH641V FH680V FH721V T2 15 N m 1 5 kg m 11 0 10 4 6 ENGINE TOP END Specifications Item Service Limit 451 FH500V FH531V Cylinder Head Cylinder compression MIN 390 kPa 57 psi MIN Cylinder head warp 0 05 mm 0 002 in Valves Valve head thickness Intake Exhaust 0 35 mm 0 014 in Valve stem runout Intake Exhaust 0 05 mm 0 002
2. starter alignment Correct YES STARTER DOES NOT STOP IN ENGINE SWITCH OFF gt Faulty pinion clutch Replace Faulty engine Repair or replace Can stop starter by engine switch OFF NO eFaulty engine switch Faulty solenoid switch Repair or replace r Replace Faulty pinion or ring gear Incorrect starter alignment Y Faulty pinion return mechanism Repair or replace Correct Repair or replace
3. 6 10 Camshaft 6 10 Gamshaft Disassembl e Rm 6 11 Camshaft Assem D ttu aeq tutte qat 6 11 Gamshaft INSPECtON ce statics C 6 11 Camshaft Bearirig Journal Wear iie dc ine cec edere d ce aaa ce uen se a doe dine ue Rn eed he 6 11 Crankshaft Connecting Rod 2 i EIER Ep gea nrbem at dete Been 6 13 Connecting Rod Removal 2 o nette rm ened 6 13 Connecting Rod Installation 6 13 e eh Awe a ei eee i RR ae 6 13 Crankshatt Installation ree Lt en RR i ee i ee 6 13 Gleaning IriSDecllOn 6 13 Connectirig Rod Bend TWISU 1 nete Pe HEB dere 6 13 Connecting Rod Big End Crankpin Width 6 14 Connecting Rod Big End Bearing Crankpin 6 14 ier soudage rtm 6 15 Grankshaft Main Jo urnal Wear 1 Ee tee Foe eed atendido 6 15 Crankpini Resizing ascii enon pee E ur nra etie eder ipe GN AN ie ru e les 6 16 6 2 CAMSHAFT CRANKSHAFT Exploded View 2 1 Key A m NN C5 CC 20 Q CAMSHAFT CRANKSHAFT 6 3 Exploded View FH451V FH500V FH531V T1 5 9 N m 0 6 kg m 52 in Ib T2 25 N m 2 6 kg m 19 0 f
4. Arq e da ween it Wa ge eire eva 7 15 Regulator Resistance Rep ade Lo eere AR Ee 7 16 Ignition Goil Retoval 2 eere ete efe diee BG See terrre rte D deer rede 7 18 Ignition Coil Installation naue aee nao dio qu 7 18 Ignition Coil Inspection e rentre RUE CDU Ue da IRURE EM 7 19 Spark Plug Cleaning and Inspection nennen rennen nnne 7 19 Spark Plug Gap Inspection 4 4 tre debe ed ete m Oe mE OR deno I fees 7 19 Starter T 7 20 Starter Motor Removal ayer 7 20 Starter Motor Installations oit gt ite c etie d eite dee 7 20 Starter Motor Disassembly eee tette Fee E HAE Le Lune eto rne o ede Y rp Ri dae 7 20 Starter Motor Assembly ne de oa ER e e e der rie ene a Ae dee ED do eon aaa 7 21 Starter Motor Brush Irispection entero eet deena 7 21 Brush Spring Inspection s irt chet it atin ait te edt teen aig ce a eges 7 21 Armature Inspection Steen ec rh Ee ET te c d ehe 7 21 Yoke AssSemibly Inspectioris iii b eee do pee drei 7 23 Pinion Glutch Inspection ssa eoe doen eeu dementis 7 23 R coil St rter Hemoval nre eee eg e me 7 24 Recoil Starter Installatiori t
5. ete ee 4 15 Valve Seat ch tics ck de Se ee ee ih eee arith het 4 15 Valve Head Thickness wa aA tee a ient p 4 17 Valve Stem ihe 4 18 Valve Stem Diameter 2 ee Se ee ee a eee ee ee as 4 18 V lve Guide Inside Diameter eed ER Dee a een eU rect Pete Ue 4 18 Valve Spring Inspection 5 noie ehe eet on ete dei ee RU la ieee 4 18 GylindersBIStOnitui rebut A oct ates tah e tod pice cats LN Ac 4 19 PIStOMREMOVAl tee ode DEEP PORC ORE 4 19 Piston Installation ato o See ing quite dieta aad efte andes 4 20 Piston CylindersSeizUre 4 21 Piston Cleaning rii ttt o tet eda dete eid a aei edet estne es 4 22 Piston Ring and WOar nce tetro rete D E EXER eu aba eu pp E Ta EYE dvd se 4 22 Piston Ring End cei tac Cnr iei e e hab ean I ap P din 4 23 Piston Pin Piston Pin Hole and Connecting Rod 4 23 4 24 Oylinder Inside Diameter eniai rt enge ceret eese cae ree rock sepe Pec vue pee ne ed sty 4 24 Cylinder Bonno and Honing s ned eet bite epe endete eae 4 25 Muffler Exhaust Pipe
6. When removing the reel be careful that the recoil spring B under the reel does not fly loose and cause injury The spring is under great pressure NOTE There should be no spring tension on the reel when removing it If tension is felt push the reel back into place and gently wiggle it until the reel can be easily removed Slowly lift the reel straight up out of the case AWARNING If the recoil spring cassette is sticking with the reel be careful that the cassette does not drop Be careful that the recoil spring does not fly loose from the cassette and cause injury The spring is under great pressure Slowly lift the recoil spring cassette straight up out of the case or reel If the recoil spring A must be removed from the cassette hold the cassette with the opening side facing downward in a suitable container and tap the cassette to remove the recoil spring Recoil Starter Assembly AWARNING Wear gloves during the recoil spring installation to avoid injury The recoil spring must be assembled with great pressure Lightly grease the recoil spring Set the recoil spring into the spring cassette Wind the rope clockwise A on the reel and hold the rope end with tape Install the spring cassette on the reel so that the tongues on the cassette fit in the openings in the reel 7 26 ELECTRICAL SYSTEM Starter System
7. FUEL SYSTEM 2 3 Exploded View FH451V 500 FH531V 1 4 5 6 8 9 10 Pilot Screw Pilot Air Jet Main Air Jet Main Jet Pilot Jet Solenoid Valve 0 7 0 07 kg m 6 in Ib 1 0 N m 0 10 kg m 9 1 3 N m 0 13 kg m 11 1 7 N m 0 17 kg m 15 in Ib 2 0 0 20 kg m 17 in Ib 3 4 0 35 kg m 30 in Ib 3 9 N m 0 40 kg m 35 in Ib 6 9 0 70 kg m 61 in Ib 7 8 0 80 kg m 69 in Ib 8 8 0 90 kg m 78 in Ib 2 4 FUEL SYSTEM Exploded View FH601V FH641V FH680V FH721V FUEL SYSTEM 2 5 Exploded View FH601V FH641V FH680V FH721V 1 oak WP 1 3 9 N m 0 40 kg m 35 in Ib T3 T4 5 6 Pilot Screw Pilot Air Jet Main Air Jet Main Jet Pilot Jet Solenoid Valve 1 0 0 10 kg m 9 2 0 0 20 kg m 18 in Ib 19 N m 1 9 kg m 14 ft lb 20 N m 2 0 kg m 15 ft lb 6 9 0 70 kg m 61 in Ib 2 6 FUEL SYSTEM Exploded View 2 am aum a mmc FUEL SYSTEM 2 7 Exploded View FH451V FH500V FH531V T5 2 0 N m 0 20 kg m 17 T8 5 9 N m 0 60 kg m 52 in Ib T9 7 8 N m 0 80 kg m 69 in Ib FH601V FH641V FH680V FH721V T5 2 0 N m 0 20 kg m 17 T8 5 9 N m 0 60 kg
8. the crankpin width is more than the service limit replace the crankshaft Crankpin Width Model Service Limit FH451V 500V 531V 39 50 mm 1 56 in FH601V 641V 680V 721V 43 1 mm 1 697 in Connecting Rod Big End Bearing Crankpin Wear Apply a light film of oil on the thread of the cap bolts Install the cap bolts and tighten the bolts to the specified torque see Piston Installation in Engine Top End chapter e Measure the inside diameter A of big end at several points with telescoping gauge or inside micrometer If the inside diameter is more than the service limit replace the connecting rod with a new one Connecting Rod Big End Inside Diameter Model Service Limit FH451V 500V 531V 35 055 mm 1 380 in 601 641 680V 721V 38 055 mm 1 498 in CAMSHAFT CRANKSHAFT 6 15 Crankshaft Connecting Rod e Measure the crankpin outside diameter A O Use a micrometer to measure several points around the crankpin circumference If the crankpin diameter is less than the service limit replace the crankshaft with a new one Crankpin Outside Diameter Model Service Limit FH451V 500V 531V 34 94 mm 1 3756 in FH601V 641V 680V 721V 37 94 mm 1 494 in Crankshaft Runout Measure the crankshaft runout Set the crankshaft in a flywheel alignment jig or on blocks gauge Set a dial gauge against both bearing journals Turn the
9. Carburetor Carburetor Disassembly Assembly FH451V 500V 531V e Refer to the illustration shown for disassembly and assembly e There are several passage plugs Ball plugs in the carburetor body Do not remove e Before disassembly mark the out side of choke valve and throttle valves for assembling them e Replace the pilot screw in accordance with the following procedure if necessary O Carefully mark the position of the pilot screw limiter on the carburetor body so that it can be installed and set to its original position later Remove the limiter Be careful not to turn pilot screw at this point O Turn the pilot screw clockwise and count the number of turns until screw is gently seated in the pilot passage Record the number of turns needed to closed the screw O Turn out the pilot screw to replace it with anew one O Install the new pilot screw until the screw is gently seated Then open the screw the same number of turns as recorded prior to removal O Align the limiter with the mark on the carburetor body to install taking care not to turn the pilot screw e Install the choke valve and throttle valve on the shaft as the out side mark of them facing out side e Drive the float pin so that it s big diameter side faces the engine flange side e The fuel inlet valve seat is pressed into the carburetor body and is not replaceable e Assemble carburetor parts which recommended tightening torque see Exploded View
10. e Be sure to replace any oil seal removed with a new one O Install the oil seal so that the marks A face out Pack some amount of a high temperature grease B into the space between the seal lip C and dust lip D Press in the new oil seal using a press or suitable tools until it is flush with flange surface E Do not damage the seal lips When replacing the oil seal A of the governor shaft note the following O Install the oil seal into the crankcase cover B after the governor shaft is inserted in the cover and so that the marks C face out O The depth is 0 1 mm 0 0 04 D When installing the governor shaft and plate in the crankcase cover see Fuel System chapter 6 6 CAMSHAFT CRANKSHAFT Crankcase Check to see that the crankcase dowel pins A are in place on the crankcase Install the gasket on the crankcase e Install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence shown FH451V 500V 531V Torque Crankcase Cover Bolts 25 2 6 kg m 19 0 ft lb Do not turn one screw down completely before the others as it may cause the crankcase cover to warp e Install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence shown FH601V 641V 680V Torque Crankcase Cover Bolts 25 2 6 kg m 19 0 ft lb Do not turn one screw down completely before the others as it
11. 7 20 ELECTRICAL SYSTEM Starter System Starter Motor Removal Remove the mounting bolts A and pull the starter motor from the engine Starter Motor Installation Clean the starter motor and engine mounting flanges to ensure good electrical contact and tighten the mounting bolts Torque Starter Motor Mounting Bolts 15 N m 1 5 kg m 11 0 ft Ib Starter Motor Disassembly Remove Through Bolts and Nuts A Brush Plate B York C Cap D While the collar A is pushing remove the snap ring e Remove Spring A Pinion Assembly B Washer C Bracket D Armature E ELECTRICAL SYSTEM 7 21 Starter System Starter Motor Assembly e Assembly is the reverse of disassembly Apply a small amount of grease to the armature shaft e Do not reuse the snap ring B Replace it with a new one Check the cap and replace it with a new one if damaged e Fit the projection A on the bracket into the notch B in the yoke e Press the springs and holding the brush leads with suitable clips e Put the washer C among the brushes e Fit the projection D on the brush plate into the notch E in the yoke Starter Motor Brush Inspection e Measure the overall length of each brush A If the brushes are shorter than the service limit replace them Brush Length Service Limit 6 4 mm 0 25 in Brush Spring Inspection Inspect the b
12. Coat the face of valve sparingly with a fine lapping compound Use the vacuum cup tool A to grip top of the valve 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 When lapping is completed wash all parts in solvent to remove lapping compound Dry the parts thoroughly 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 When the engine is assembled be sure to adjust the valve clear ances see Valve Clearance Adjustment Valve Head Thickness e Remove the valve see Valve Mechanism Removal Installation Measure the thickness of the valve head If the valve head thickness valve margin A is less than the service limit replace the valve Valve Head Thickness Service Limit IN EX 0 35 mm 0 014 in 4 18 ENGINE TOP END Valves Valve Stem Runout Support the valve in blocks at each end of the stem Position a dial gauge perpendicular to the stem e Turn the valve and read the variation on the dial gauge If the stem runout is greater than service limit replace the valve Valve Stem Runout Service Limit IN EX 0 05 mm 0 002 in Valve Stem Diameter e Measure the diameter of the valve stem A in two dir
13. Lightly grease the shaft A e Put the reel into the case with the round peg B aligned with the spring inner tongue C Turn the reel clockwise until you feel the hang hook on the catch Install Return Springs A and Pawls B Washer C and Center Spring D e Lightly grease the center spring e Install Retainer A Washer B Screw C Torque Recoil Starter Retainer Screw 7 8 0 80 kg m 69 in Ib e Turn the reel two turns counterclockwise to preload the recoil spring e While holding the reel to keep it from unwinding feed the end of the rope through the hole in the case e Clip the rope as shown to hold it e Install the handle A and secure it with a knot B e Remove the clip C to release the rope TROUBLESHOOTING 8 1 Troubleshooting Table of Contents Engine Troubleshooting Guide i iuit diete t po dee eee ter ite oe ert aed eh cei 8 2 Starter Motor Troubleshooting 8 6 8 2 TROUBLESHOOTING Engine Troubleshooting Guide If the engine malfunctions check if the way the engine is used is correct If engine malfunctions even if engine is used correctly systematically carry out troubleshooting starting with simple points This chart describes typical troubleshooting procedures Do not unnecessarily disassemble carburetor magneto or engine unless it has been found to be the cause of malfunctioning Engin
14. 11 072 mm 0 4359 in 19 50 mm 0 77 in ol ll Special Tool Oil Filter Wrench 57001 1249 Sealant Kawasaki Bond Silicone Sealant 56019 120 5 6 LUBRICATION SYSTEM Engine Oil Oil Filter and Oil Cooler CAUTION Engine operation with insufficient deteriorated or contami nated engine oil will cause accelerated wear and may result in engine seizure and accident Before starting the engine for the first time add oil The engine is shipped dry Preoil the engine to force all air from the internal oil passages and the oil filter Fill fresh engine oil to the specified level see Oil Level Inspection e Run the engine at slow speed 2 minutes Stop the engine and check the oil level Oil Level Inspection Place the engine a level surface e Remove the oil filler cap A and wipe its dipstick B with a clean cloth Insert the dipstick into tube without screwing it in then check the oil Level The oil level should be the operating range grid area on the dipstick If the oil level is ADD range E add enough engine oil to bring oil level to the operating range CAUTION Do not add more oil above the operating range Excess oil will cause a smoking condition Use the same type and make of oil that is already in the engine NOTE If the engine oil type and make are unknown use any brand of the specified oil to top up the level in prefe
15. Because of the danger of highly flammable liquids do not use gasoline or a low flash point solvent to clean the element e Remove the foam element and the paper element Clean the foam element A in a bath of detergent and water and let the element air dry throughly before install it 2 26 FUEL SYSTEM Air Cleaner Clean the paper element A by tapping it gently on a flat surface to remove dust If the element is very dirty replace it with a new one CAUTION Do not use compressed air to clean the paper element Do not oil the paper or foam element Element Cleaning and Inspection FH601V 641V 680V 721V See Element Cleaning and Inspection FH451V 500V 531V Foam Element A Paper Element B Cleaner Body Removal FH451V 500V 531V Remove the elements see Element Removal Remove the cleaner body mounting screws A holder plate nuts and holder plate C e Pull the breather tube A off the pipe at the back of the body and remove the cleaner body B FUEL SYSTEM 2 27 Air Cleaner Cleaner Body Removal FH601V FH641V FH680V FH721V e Remove the element see Element Removal Remove the clamp A and take off the breather tube e Loosen nuts and remove the solenoid valve wire D e Unscrew the bolts E and remove the intake pipe F Cleaner Body Installation FH451V 500V 531V e Connect the breather tube from the crankc
16. Ignition system Transistorized fly wheel magneto RFI Per Canada and U S A requirements Starting system Electric starter and or recoil starter Charging system 12 V 13 amps with regulator Carburetor Float type fixed main jet Float type fixed main jet two barrel Diaphragm type pulse pump Air cleaner Dual stage element dry type Lubrication system Pressure feed by positive displacement pump Oil pressuer switch ON OFF switch Oil capacity 1 8 L 1 9 US qt 1 9L when engine is 2 0 US qt completely dry Cooling system Forced air cooling by fan Dimensions LxWxH 425 mm x 359 mm x 324 mm 458 mm x 430 mm x 381mm Electric starter model 16 7 in x 14 1 in x 12 8 in 18 0 in x 16 9 in x 15 0 in 425 mm x 359 mm x 361 mm Recoil starter model 16 7 in x 14 1 in x 14 2 in Dry weight Electric starter model 34 kg 75 Ib 40 5 kg 89 3 1 5 41 2 kg Recoil starter model 32 kg 71 Ib 90 8 Ibs Specifications are subject to change without notice GENERAL INFORMATION 1 7 Periodic Maintenance Chart To ensure satisfactory operation over an extended period of time any engine requires normal maintenance regular intervals The Periodic Maintenance Chart below shows periodic inspection and maintenance items and suitable intervals The bullet mark designates that the corresponding item should be performed at that interval Some adjustments require the use of special tools or other equipment An e
17. Resurface 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 cylinder head must be replaced Do not turn the cutter counterclockwise or drop it against the seat or it will be dulled ENGINE TOP END 4 17 Valves e Use a 30 seat cutter A to narrow the seat width to the STD width O Turn the seat cutter one turn at a time while pressing down very lightly Check the seat width after each turn CAUTION The 30 cutter removes material very quickly Check the seat width frequently to prevent over grinding NOTE O Keep the seat width as closely as possible to the STD width Make a light pass 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 Apply machinist s dye to the valve face insert the valve and snap it closed against the seat several times The valve surface should show good contact all the way around Be sure the valve seat is centered on the valve face The position of the valve in the seat is evident after lapping the valve If the seat does not make proper contact lap the valve into seat with a vacuum cap tool
18. 1 Limiter 19 Main Nozzle 2 Pilot Screw 20 Valve Seat 3 Spring 21 Float Chamber 4 Low Idle Speed Screw 22 Gasket 5 Spring 23 Bolt 6 Seal 24 Gasket 7 Ring 25 Solenoid Valve 8 Throttle Shaft Electric Starter Model 9 Throttle Valve 26 Drain Screw 10 Screws 27 Gasket 11 Pilot Jet 28 Pin 12 Screw 29 Snap Ring 13 Choke Valve 30 Float Valve 14 Choke Shaft 31 Main Air Jet 15 Spring 32 Air Jet 16 Coller 33 Washer 17 Main jet 34 ETypeCirclip 18 Float 35 Cap 36 Earth Lead Electric Starter Model ll 2 18 FUEL SYSTEM Carburetor Carburetor Disassembly Assembly FH601V 641V 680V 721V e Refer to the illustration shown for disassembly and assembly There are several passage plugs Ball plugs in the carburetor body Do not remove e Before disassembly mark the out side of choke valve and throttle valves for assembling them 1 Plug Pilot Screw 15 Float 2 Pilot Screw 16 Gasket 3 Low Idle Speed Screw 17 Float Chamber 4 Spring 18 Screw 5 Seal 19 Clamp 6 Collar 20 Plug Main Jet 7 Throttle Valve 21 Gasket 8 Screws 22 Main Jet L 9 Throttle Shaft 23 Main Jet R 10 Choke Valve 24 Slow Jet 11 Choke Shaft 25 Drain Screw 12 Seal 26 Spring 13 Float Valve 27 Gasket 14 Pin 28 Solenoid Valve e Replace the pilot screw A in accordance with the following procedure if necessary Remove the pilot screw plug B material Stainless steel as
19. ENGINE TOP END 4 23 Cylinder Piston Measure the piston ring thickness A O Use a micrometer to measure at several points around the rings f any of the measurement are less than the service limit replace the entire set of rings Piston Ring Thickness Service Limit Top Second 1 40 mm 0 055 in NOTE When using new rings in a used piston check for uneven groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Piston Ring End Gap e Remove the piston rings e Push each ring one at a time in the cylinder bore to a point close to the bottom of the cylinder bore O Use 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 If the end gap of any ring is greater than the service limit replace the entire set of rings Piston Ring End Gap Service Limit FH451V FH500V FH531V FH601V FH641V FH680V FH721V Top 0 70 mm 0 028 in 0 65 mm 0 026 in Second 0 78 mm 0 031 in Oil 1 05 mm 0 041 in Piston Pin Piston Pin Hole Connecting Rod Wear e Remove the piston pin e Measure the diameter of the piston pin with a micrometer at several points If the outside diameter is less than service limit replace the piston pin Piston Pin Outside Diameter Service Limit 15 96 mm 0 628 in e Measure the inside diameter A of the piston pin hole
20. Piston cylinder wear piston seizure Piston ring piston ring groove ON 4 10 ENGINE TOP END Cylinder Head Cylinder Head Assembly Removal Remove Air Cleaner and Carburetor see Fuel System chapter Muffler see Muffler Exhaust Pipe Removal Intake Manifold see Fuel System chapter Spark Plug Unscrew the rocker cover mounting bolts A and remove the cover and gasket When removing the 1 2 cylinder head set each cylinder at T D C A of power stroke in Loosen the cylinder head bolts 1 4 turn in the sequence shown CAUTION If the above procedure is not followed the cylinder head may be warped during removal Repeat the sequence until all bolts are removed lift off the cylinder head assembly NOTE Mark the push rods so they can be installed in their original position during assembly Cylinder Head Assembly Installation e Clean the mating surfaces of the cylinder heads and cylinder Install the push rods in their original positions on each cylinder see Push Rod Installation Install the knock pins Set each cylinder at T D C A of power stroke in e Put a new gaskets and the cylinder head assemblies on each cylinder then let the cylinder heads with push rods aligned under the rocker arms NOTE O As the head gaskets are coated with sealing agents be careful not to damage the surfaces ENGINE TOP END 4 11 Cylinde
21. 0 80 kg m 69 in Ib e Be sure the governor shaft extend from the governor arm is approxi mately 7 mm 0 3 in H as shown Install the control panel assembly and connect the governor arm with the governor spring Governor Assembly Removal Remove the crankcase cover see Camshaft Crankshaft chapter Remove the push rod see Engine Top End chapter e Upside down the engine Remove the camshaft A e Remove Washer A Snap Ring B Sleeve C Governor Plate D Snap Ring B Steel balls E Ball Guide F Ball Plate G Governor Assembly Installation e Fit the snap rings A into the grooves securely Spin the governor plate by hand and check that the steel balls and governor plate operate freely FUEL SYSTEM 2 11 Governor Link Mechanism Governor Assembly Inspection O Visually check all governor parts for wear and damage If any parts are worm or damaged replace them Governor Shaft Removal Split the crankcase see Camshaft Crankcase chapter e Unscrew the governor shaft plate screws A and pull out the governor shaft B outside NOTE O It is not necessary to remove the governor shaft unless it is being replaced e Replace the oil seal only if the lip shows signs of leakage or it has been damaged The oil seal A must be assembled with seal lip towards inside of the engine Press in the oil seal 0 1 0 mm 0 04 in flush or
22. 641V 680 721V Torque Main Jet Plug 19 N m 1 9 kg m 14 ft lb Fuel system Cleanliness Inspection PUG Gasoline is extremely flammable and can be explosive 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 air cleaner see Cleaner Body Removal e Place a suitable container A under the drain screw B on the carburetor Turn out the drain screw a few turns to drain the carburetor and check to see if water or dirt has accumulated in the carburetor Tighten the drain screw Torque FH451V 500V 531V Drain Screw 1 3 N m 0 13 kg m 11 in Ib FH601V 641V 680V 721V Drain Screw 2 0 0 2 kg m 18 in Ib e f any water or dirt is found clean the carburetor see Carburetor Cleaning and fuel tank and check the fuel filter 2 16 FUEL SYSTEM Carburetor Carburetor Removal Gasoline is extremely flammable can be explosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove Air Cleaner and Related Parts see Cleaner Body Turn the fuel shut off valve to the OFF position Drain the carburetor e Disconnect the fu
23. 9 N m 0 6 kg m 52 in Ib Breather Valve Inspection FH601V 641V 680V 721V e Unscrew the mounting screw and remove the plate B and the breather valve e Inspect the breather valve for breakage hair crack or distortion replace it if necessary e Inspect the plate B for damage or rough contact surface replace it if necessary Inspect the valve seating surface The surface should be free of nicks or burrs e Be sure the drain hole on the breather chamber does not accumulate with slugs before installing the breather valve e Align center of the valve seat with center of the breather valve and the plate then tighten the mounting screw NOTE O The mounting screw is a self tapping one Be aware that mis threading or overtightening screw will strip the female threads and ruin the hole 6 10 CAMSHAFT CRANKSHAFT Camshaft Tappet Camshaft Tappet Removal Set the engine on a clean surface while parts are being removed Drain the oil see Lubrication System chapter e Remove Muffler see Engine Top End chapter Throttle Control Panel see Fuel System chapter Carburetor see Fuel System chapter Intake Manifold see Fuel System chapter Crankcase Cover see Crankcase Cover Removal Rocker Covers A Position the piston TDC at the end of the compression stroke Push down A the spring side of the rocker arm and move it to clear the push rod C e Remove the push
24. Be sure the end of the push rods are correctly seated on the tappets e Tighten the valve clearance adjusting nuts e Check and adjust the valve clearance 4 12 ENGINE TOP END Cylinder Head Push Rod Inspection Place the rocker arm push rod blocks that are as far apart as possible and set a dial gauge on the rod at a point halfway between the blocks Turn the rod to measure the runout The difference between highest and the lowest dial readings is the amount of runout If the runout exceeds the service limit replace the rod Rocker Arm Push Rod Runout Service Limit 0 5 mm 0 02 in Valve Mechanism Removal Installation e Remove the cylinder head assembly see Cylinder Head Assembly Removal NOTE When removing the valve mechanism parts note their position so that they may be reinstalled in their original position during assembly e Remove Valve Clearance Adjusting Nuts A Rocker Arms B e Support the valve head in the combustion chamber with a suitable block e To remove the collets A push down the valve retainer B with thumbs and remove the Collets e Remove the spring C and valve D e Remove the stem seals A NOTE It is not necessary to remove the stem seal unless it is being replaced O Valve guide B is not replaceable do no remove it e Valve Installation O Apply engine oil to the valve stem to avoid damaging the stem seal O Check to see that the va
25. FH680V FH721V Note Portion surrounded byzzzz shows procurement parts Carburetor Spark Plugs Oil Lamp 3 4W b c id 9 START ELECTRICAL SYSTEM 7 11 Precautions There are a number of important precautions that are musts when servicing electrical systems Learn and observe all the rules below Do not reverse the battery lead connections This will burn out the diodes in the electrical parts O Always check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical system tests The electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them To prevent damage to electrical parts do not disconnect the battery leads or any other electrical connections when the engine switch is on or while the engine is running Because of the large amount of current never keep the engine switch turned to the start position when the starter motor will not turn over or the current may burn out the starter motor windings Take care not to short the leads that the directly connected to the battery positive terminal to the chassis ground O Troubles may involve one or in some cases all items Never replace a defective part without d
26. FH721V Cylinder Head Cylinder compression MIN Cylinder head warp Valves Valve head thickness Valve stem runout Valve stem diameter Valve guide inside diameter Valve spring free length Rocker arm push rod rounout Cylinder Piston Piston diameter Piston ring groove clearance Piston ring thickness Piston ring end gap Piston pin outside diameter Piston pin hole inside diameter Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Top Second Top Second Top Second Oil Connecting rod small end inside diameter Cylinder inside diameter Cylinder bore out round Standard Cylinder 0 50 mm Oversize 390 kPa 57 psi MIN 0 05 mm 0 002 in 0 35 mm 0 014 in 0 05 mm 0 002 in 5 95 mm 0 0234 in 5 93 mm 0 0233 in 6 08 mm 0 239 in 31 0 mm 1 22 in 0 5 mm 0 02 in 74 99 mm 2 952 in 0 18 mm 0 007 in 0 16 mm 0 006 in 1 40 mm 0 055 in 0 65 mm 0 026 in 0 78 mm 0 031 in 1 05 mm 0 041 in 15 96 mm 0 628 in 16 08 mm 0 633 in 16 05 mm 0 632 in 75 28 mm 2 964 in RE UP 75 78 mm 2 983 in 0 056 mm 0 0022 in Standard Valve clearance Valve seating surface angle Valve seating surface width Valves guide inside diameter Oylinder bore diamter standard cylinder Standard cylinder 0 50 mm Over size Intake Exhaust Intake Exhaust Intake Exaust Intake Exhaust FH6
27. If any rough spots are found during above inspection wash the valve clean with a high flash point solvent and blow out any foreign particles that may be in the valve with compressed air AWARNING 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 LUBRICATION SYSTEM 5 11 Oil Pump Relief Valve If cleaning does not solve the problem replace the relief valve parts If necessary put the ball in position and lightly tap the ball with suitable tools to form a perfect seat e Measure free length A of the spring with a vernier caliper If the free length of the spring is less than the service limit replace the spring Relief Valve Spring Free Length Service Limit 19 50 mm 0 77 in 5 12 LUBRICATION SYSTEM Oil Screen Oil Screen Removal Remove the crankcase cover see Camshaft Crankcase chapter e Unscrew the mounting bolts A and remove the oil pump parts assembly Remove the oil screen Oil Screen Installation 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 with high flash point solvent and remove any particle
28. Jet No Altitude FH451V FH531V FH601V FH500V 641 FH680V FH721V 0 1 000 m 0 3 000 ft 1 000 2 000 3 000 6 000 2 000 6 000 Main Jet Replacement e Place the engine equipment on a level surface Close the fuel shut off valve in the equipment Drain the fuel in the carburetor completely by unscrewing the drain screw at the bottom of the float chamber Remove the carburetor see Carburetor Removal e Unscrew the float chamber bolt A and take off the float chamber B e Unscrew the solenoid valve and take off the valve and gasket Electric Starter Model FUEL SYSTEM 2 15 Carburetor e Using a proper blade screw driver carefully replace the main jet A with a new one for altitude expected Tighten the main jet to the specification see Carburetor Disassembly Assembly Notes Install the float chamber gasket and solenoid valve FH451V 500V 531V e Remove the carburetor see Carburetor Removal e Unscrew the main jet plugs C and take off the main jet plugs and gaskets e Make sure that L L or R R mark on the float chamber is shown the main jet position e Using a proper blade screw driver carefully replace the main jet D with a new one for altitude expected Tighten the main jet to the specification see Carburetor Disassembly Assembly Install the gasket and the main jet plug FH601V
29. Limit 40 470 mm 1 5933 in e Measure the thickness B of the outer rotor with a micrometer at several points If the rotor thickness is less than the service limit replace both the inner and outer rotor Outer Rotor Thickness Service Limit 9 830 mm 0 3870 in 5 10 LUBRICATION SYSTEM Oil Pump Relief Valve Measure the inside diameter A of the pump housing with a inside micrometer at several points If the inside diameter is more than the service limit replace the crankcase cover Pump Housing Inside Diameter Service Limit 40 801 mm 1 6063 in Measure the depth of the pump housing with a depth micrometer at several points any of measurement is more than the service limit replace the crankcase cover Pump Housing Depth Service Limit 10 230 mm 0 4028 in Measure the outside A diameter of the pump shaft with a micrometer at several points If the diameter is less than the service limit replace the pump shaft Pump Shaft Outside Diameter Service Limit 10 923 mm 0 4300 in Measurer the inside diameter A of the pump shaft bearing in the crankcase cover with a inside micrometer at several points the inside diameter is more than the service limit replace the crankcase cover Pump Shaft Bearing Inside Diameter Service Limit 11 072 mm 0 4359 in e Visually inspect the relief valve spring steel ball and valve seat in the crankcase cover
30. Note a location of the arrow match mark A on the piston head in relation to K Mark B on the connecting rod No 1 cyl K Mark on the connecting rod is face to face with No 2 cyl K Mark on the connecting rod Keep parts together as a set Remove one of the piston pin snap rings A with needle nose pliers e Remove the piston by pushing the piston pin A out the side from which the snap ring was removed 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 and then push up on the opposite side of the ring A to remove it Remove the 3 piece oil ring with your thumbs in the same manner 4 20 ENGINE TOP END Cylinder Piston Piston Installation Install the expander A in the piston oil ring groove so that the expander ends B touch together never overlap Install the upper and lower steel rails There is or Down to the rails They can be installed either way Do not mix up the top and second rings Install the second and top rings as shown The rings should turn freely in the grooves A Piston Head B Top Ring for FH451V 500V 531V C Second Ring for FH451V 500V 531V D Top Ring for FH601V 641V 680V 721V E Second Ring for FH601V 641V 680V 721V e Align the piston and rings with the piston ring end g
31. 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 7 High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent commonly available in North America is Standard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent 8 Gasket O Ring Do not reuse a gasket or O ring once it has been in service The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks 9 Liquid Gasket Non Permanent Locking Agent Follow manufacturer s directions for cleaning and preparing surfaces where these compounds will be used Apply sparingly Excessive amounts may block engine oil passages and cause serious damage An example of a non permanent locking agent commonly available in North America is Loctite Lock n Seal Blue 10 Press A part installed using a press or driver such as a journal should first be coated with oil on its outer or inner circumference so that it will go into place smoothly 11 Ball Bearing When installing a ball bearing the bearing race which is affected by friction should be pushed by a suitable driver This prevents severe stress on the balls and races and prevents
32. c 5 7 Gil Gooler Installati rg det ere re n iet EM AR ENE 5 7 Pressurized Lubrication System nite pede terere die be tebe besten save diese tas enn Pea be deo teense 5 8 Oil Pressure Meas re mlent ntt ach eee Dt oed DON 5 8 Oil Pressure Switch Aspecto 3 de rentre e e eode ee he elie eden dee 5 8 oic TER Er ee ere 5 9 Oil Pump Relief Valve 5 9 Oil Pump Relief Valve 1 5 9 Oil Pump Relief Valve 5 9 OI SOKO dioi iecit Dt ee oerte 5 12 Oil Sereen Remova epa ap a ED 5 12 Oil SereenNStallatiOi nanmi etn UR c EN E bs 5 12 Cleaning and Inspection ep ed ER ERR 5 12 5 2 LUBRICATION SYSTEM Exploded View LUBRICATION SYSTEM 5 3 Exploded View FH451V FH500V FH531V T1 T2 4 5 6 T7 8 3 9 0 40 kg m 35 in Ib 6 9 0 7 kg m 61 9 8 1 0 kg m 87 in Ib 20 N m 2 0 kg m 14 5 ft lb 39 N m 4 0 kg m 29 ft lb 17 N m 1 7 kg m 12 0 ft lb See the text 5 9 0 6 kg m 52 in Ib FH601V FH64
33. crankshaft slowly to measure the runout The difference between the highest and lowest dial gauge readings TIR is the amount of runout If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Service Limit 0 05 mm 0 002 in TIR Crankshaft Main Journal Wear Measure both main journals at several points around the journal circumference x If the journal diameter is less than the service limit replace the crankshaft with a new one PTO Side Crankshaft Journal Diameter A Service Limit FH451V 500V 531V 34 90 mm 1 374 in FH601V 641V 680V 721V 39 896 mm 1 571 in Flywheel Side Crankshaft Journal Diameter B Model Service Limit FH451V 500V 531V 34 93 mm 1 375 in FH601V 641V 680V 721V 39 896 mm 1 571 in 6 16 CAMSHAFT CRANKSHAFT Crankshaft Connecting Rod Crankpin Resizing Crankpin can be resized to accept 34 5 mm 1 3583 in dia under size connecting rod The crankpin should be reground if the crankpin is SO much undersize and so much scored that a lapping operation will prove unsatisfactory Reground can be done by a reliable repair shop e Before sending the crankshaft inspect the crankpin for cracks If any cracks no matter how small are found the crankshaft must be rejected The final finishing dimensions should be shown in the table Finishing Dimensional Specifications FH451V 500 FH531V 34 470 34 457
34. follows Punch a hole in the plug and pry it out with an awl or other suitable tool O Turn in the pilot screw and count 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 assembling O Turn in the new pilot screw A fully but not tightly and then back it out the same number of turns counted during disassembly O Install a new pilot screw plug B 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 Install 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 may be fixed FUEL SYSTEM 2 19 Carburetor Drive the float pin so that it s big diameter side faces the throttle shaft lever side The fuel inlet valve seat is pressed into the carburetor body and is not replacable e Assemble carburetor parts which recommended tightening torque see Exploded View Carburetor Cleaning AWARNING 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 o
35. for damage Flange sealing surfaces should be smooth and free of burns and nicks Replace the gasket if necessary Turn the throttle and choke shafts to check that the throttle and choke butterfly valves move smoothly If the valves do not move smoothly replace the carburetor body and or throttle shaft and choke shaft assembly Check the gasket on the carburetor body If the gasket is not in good condition replace it Check the other parts of the carburetor for wear or damage Replace the part if necessary Clean and check the float level as follows CAUTION Do not push down on the float during float level checking With the float A assembly installed onto the carburetor body 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 If the float position is not correct replace the float with a new e Inspect the float valve for excessive wear or damage The tip should be smooth without any grooves scratches or tears The rod at the other end of the needle should move smoothly when push in and released If either the needle or the seat is worn or damaged replace the float assembly and carburetor body as a set Inspect the tapered portion A of the pilot screw for wea
36. inspect the rest of the lubrication system Cil Pressure 241 to 310 kPa 35 to 45 psi Oil Pressure Switch PT 1 8 Taper Pipe Threads Oil Pressure Switch Inspection When the oil pressure falls below 98 kPa 14 2 psi the oil pressure switch activates the oil warning lamp to alert the operator or lubricating problem To check the oil warning system insert the switch key into the OFF position of the engine switch then turn it to the RUN position The warning light must be illuminated When the engine is running be sure the warning light is OFF If the warning light comes on stop the engine immediately and check the oil level e When starting the engine note the warning light on dash carefully If the warning light is on in the started engine in spite of adequate oil level check the lead from the pressure switch to the warning light for short circuit and or check the pressure switch and replace damaged part If the light is not on at the moment of the engine switch operation check all leads of the warning light circuit or bulb and replace damaged parts LUBRICATION SYSTEM 5 9 Oil Pump Relief Valve Oil Pump Relief Valve Removal Remove the crankcase cover see Camshaft Crankshaft chapter e Unscrew the mounting bolts and remove the oil pump parts assembly pump gear pump cover plate pump shaft pins and rotors Take off the relief valve spring and ball e Disassemble t
37. m 52 in Ib T9 7 8 N m 0 80 kg m 69 O Apply engine oil 2 8 FUEL SYSTEM Specifications Standard FH601V FH641V FH680V Item FH451V FH500V FH531V FH721V Caburetors Specifications Make type MIKUNI B24T1 Nikki 621266 Throttle bore diameter 24 mm 0 94 in 26 1 02 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 High idle speed Air Cleaner Type Pre cleaner Second stage cleaner Fuel Fuel requirement 16 mm 0 63 in 125 48 8 01 7 01 2 21 4 18 0 71 116 3 43 8 01 4 20 8 13 8 Float parallel to carburetor body 1550 r min rpm 3600 r min rpm Dual stage filtration system Foam element Paper element Unleaded regular grade gasoline 21 mm 0 83 in L 136 R 140 L 46 R 44 1 7 1 1 L 2 1 4 R 1 1 4 Fuel Pump Type Pulse diaphragm pump Governor Type Flyweight all speed governor 1 Idle speeds may vary depending on each equipment Refer to the equipment specification FUEL SYSTEM 2 9 Governor Link Mechanism Control Panel Assembly Removal Remove Air Cleaner see Cleaner Body Removal Air Cleaner Mount Bracket Bolts A Air Cleaner Mount Bracket B Earth Lead Starter Model Control Panel Mounting Bolts C e Remove the control p
38. may cause the crankcase cover to warp Inspection Measure the inside diameter A of the PTO shaft bearing on the crankcase cover at several points This bearing is not replaceable Replace the crankcase cover if the inside diameter is more than the service limit PTO Shaft Bearing Inside Diameter Model FH451V 500V 531V Service Limit 35 15 mm 1 384 in 601 641V 680V 721V 40 15 mm 1 581 in Measure the inside diameter A of the crankshaft journal bearing on the crankcase at several points This bearing is not replaceable Replace the crankcase if the inside diameter is more than the service limit Crankshaft Journal Bearing Inside Diameter Model Service Limit FH451V 500V 531V 35 15 mm 1 384 in 601 641V 680V 721V 40 15 mm 1 581 in CAMSHAFT CRANKSHAFT 6 7 Crankcase Cleaning e Remove Camshaft and Tappets see Camshaft Tappet Removal Crankshaft see Crankshaft Removal 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 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 6
39. rods and mark them so they can be installed in their original positions during assembly e Turn the crankcase up side down so that the tappets will fall away from the cam lobes e Pull the camshaft A out of the crankcase e Remove the tappets A and mark them so they can be installed in their original positions during assembly Camshaft Tappet Installation Apply engine oil to the following Tappet Journal Camshaft Journal Cam Lobe Surface Camshaft Gear Align the punch marks A on the crankshaft gear and camshaft gear Install the shim on the camshaft CAMSHAFT CRANKSHAFT 6 11 Camshaft Tappet Camshaft Disassembly e Remove the governor assembly see Fuel System chapter e Remove Spring A O Do not remove the ACR automatic compression release weight B Camshaft Assembly e Install the governor assembly see Fuel System chapter e After assembling the camshaft check the following items O The governor plate A must move freely O While shaking the camshaft ACR weight B swings smoothly Camshaft Inspection e Check the camshaft gear A for pitting fatigue cracks burrs or an evidence of improper tooth contact Replace the shaft if necessary e Check the top of the cam lobes B for wear burrs or uneven contact Replace the shaft if necessary Camshaft Bearing Journal Wear Measure the height of each cam lobe If the cam height is less than the service limit for
40. seats can be refaced Lap the valves to the seats after refacing e Coat the valve seat with machinist s dye e Push the valve into the guide e Rotate the valve against the seat with a 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 NOTE O The valve stem and guide must be in good condition or this check will not be valid If the valve seating pattern is not correct repair the seat Valve Seating Surface Width STD Good Too Wide FH451V FH500V FH531V Inlet Exhaust 0 6 0 9 mm 0 024 0 035 in FH601V FH641V 680 FH721V Inlet 0 8 1 4 mm 0 03 0 05 in Too Narrow Uneven Exhaust 1 1 1 6 mm 0 04 0 06 Valve Seat Repair e Follow the manufacture s instructions for use of valve seat cutters Special Tools Intake Valve Seat Cutter 45 935 0 57001 1116 Outside Cutter 30 933 0 57001 1199 Exhaust Valve Seat Cutter 45 930 0 57001 1187 Outside Cutter 30 930 0 57001 1120 Valve Seat Cutter 26 0 57001 1360 Valve Seat Cutter Holder Bar 57001 1128 If the manufacture s instructions are not available use the following procedure 4 16 ENGINE TOP END Valves Seat Cutter Operating Cares 1 This valve seat cutter is designed only for valve seat repair Therefore the cutter must not be used for other purposes 2 Do not drop or hit the valve seat cutter or the di
41. spark plugs Check and clean oil cooler fins FH721V engines Change Oil filter Change air cleaner paper element 1 Check and adjust vlave clearance e Clean and lap valve seating surface e Clean combustion chamber e 1 Service more frequently under dusty 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 GENERAL INFORMATION 1 9 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 L Apply a non permanent locking agent to the threads M Apply a molybdenum disulfide lubricant grease or oil to the threads seated surface or washer Apply an oil to the threads seated surface or washer S Tighten the fasteners following the specified sequence SS Apply silicone sealant FH451V 500 FH531V FH451V FH500V FH531V Fastener Torque Remarks N m ft lb Fuel System Choke Valve Screw 0 7 0 07 6 in Ib Throttle Valve Screws 1 0 0 10 9 in Ib Pilot Jet 1 7 0 17 15 in lb Main Jet 0 7 0 07 6 in Ib Main Air Jet 0 7 0 07 6 in Ib Main Nozzle 2 0 0 20 17 in lb Pilot Air Jet 0 7 0 07 6 in Ib Drain Screw Carburetor 1 3 0 13 11 in lb Earth Lead Screw 3 4
42. 0 35 30 in Ib Carburetor Side Fuel Shut Off Solenoid Valve 6 9 0 70 61 in Ib Carburetor Float Chamber Mounting Screw 8 8 0 90 78 in lb Carburetor Governor Arm Clamp Nut 7 8 0 8 69 Governor Shaft Plate Screws 2 0 0 20 18 in Ib Holder Plate Nuts Air Cleaner 5 9 0 60 52 in Ib Carburetor Mounting Intake Manifold Mounting Bolts 5 9 0 6 52 in Ib Cleaner Body Mounting Screws 3 4 0 35 30 in Ib Control Panel Mounting Bolts 5 9 0 6 52 in Ib Cooling System Engine shoroud Bolt M8 15 1 5 11 Engine shoroud Bolts M6 5 9 0 6 52 in Ib Plug Bolt Engine shroud 5 9 0 6 52 in Ib Plug Screw Engine shroud 3 4 0 35 30 in Ib Engine Top End Cylinder Head Bolts 25 2 6 19 0 Valve Clearance Lock Screws 6 9 0 70 61 in Ib Connecting Rod Big End 5 9 0 60 52 Cap Bolts Rocker Arm Bolts 28 2 8 20 Rocker Cover Mounting Bolts 5 9 0 6 52 in lb Exhaust Pipe Flange Nuts 15 1 5 11 Spark Plugs 22 2 2 16 1 10 GENERAL INFORMATION Torque and Locking Agent FH451V FH500V FH531V Fastener Torque Remarks N m ft lb Lubrication System Engine Drian Plugs Plastic 6 9 0 70 61 in Ib Engine Drain Plug Metal 20 2 0 14 5 Engine Drain Plug Joint Plastic 17 1 7 12 0 Engine Drain Plug Joint Metal 39 4 0 29 Oil Pressure Switch 9 8 1 0 87 in lb SS Oil Passage Plug 3 9 0 40 35 in Ib Oil Pump Cover Plate Mounting Bolts 5 9 0 6 52 in Ib Oil Filter in the text Camshaft Crankshaft Crankcase C
43. 01V FH641V FH680V FH721V 0 075 0 125 mm 0 003 0 005 in 45 0 8 1 4 0 03 0 06 in 1 1 1 6 mm 0 04 0 06 in 6 00 6 012 mm 0 2362 0 2367 in 75 18 75 20 mm 2 960 2 961 in 75 68 75 70 mm 2 979 2 980 in 4 8 ENGINE TOP END Specifications Special Tools Compression Gauge 57001 221 Compression Gauge Adapter M14 x 1 25 57001 1159 Piston Ring Pliers 57001 115 Piston Ring Compression Grip 57001 1095 Piston Ring Compression Belt 67 79 57001 1097 Valve Seat Cutter Holder Bar 57001 1128 Valve Seat Cutter Holder 6 57001 1360 Valve Seat Cutter 45 35 0 57001 1116 Valve Seat Cutter 30 633 0 57001 1199 Valve Seat Cutter 45 430 0 57001 1187 Valve Seat Cutter 30 30 0 57001 1120 ENGINE TOP END 4 9 Cylinder Head Compression Measurement Before measuring compression do the following Be sure the battery is fully charged Thoroughly warm up the engine so that engine oil between the piston and cylinder wall will help seal compression as it does during normal running Stop the engine e Disconnect the spark plug caps of each cylinder and remove the spark plugs e Attach the compression gauge assembly firmly into one plug hole Special Tool Compression Gauge 57001 221 A Compression Gauge Adapter 57001 1159 B Ground the spark plugs to the engine avoid fire do not ground the s
44. 10 a 20C 30 40 qu EET 30 SET 40 E 4F i4F 32 F 50F 68F 86 104 721 5751 5 8 LUBRICATION SYSTEM Pressurized Lubrication System The engine lubrication circuit is a pressurized system consisting of a positive displacement pump which picks up oil through a filter screen from the crankcase The oil is pumped to a replaceable oil filter cartridge through the engine s oil passages to lubricate internal components and return to the crankcase A pressure relief valve is used between the oil pump and oil filter to relieve excessive oil pressure by returning excess oil to the crankcase see Oil Flow Chart Oil Pressure Measurement Remove the oil pressure switch or oil passage plug from the crankcase e Install an appropriately sized oil pressure gauge adapter A and oil pressure gauge B Run the engine and allow warm up completely e Run the engine at fast idle speed and read the oil pressure gauge e Stop the engine e Remove the oil pressure gauge and adapter e Apply silicone sealant to the threads of the pressure switch and tighten it or tighten the plug Sealant Kawasaki Bond Silicone Sealant 56019 120 Torque Oil Pressure Switch 9 8 1 0 kg m 87 Oil Passage Plug 3 9 N m 0 40 kg m 35 in Ib If the oil pressure is below the specification inspect the oil pump and relief valve If the oil pump and relief valve are not at fault
45. 1V FH680V FH721V T1 T2 4 5 6 8 9 56 3 9 N m 0 40 kg m 35 6 9 0 7 kg m 61 in Ib 9 8 1 0 kg m 87 in Ib 20 N m 2 0 kg m 14 5 ft lb 39 N m 4 0 kg m 29 ft lb 17 N m 1 7 kg m 12 0 ft lb See the text 5 9 0 6 kg m 52 in Ib 44 N m 4 5 kg m 33 ft lb Apply engine oil Apply silicone sealant 5 4 LUBRICATION SYSTEM Engine Oil Flow Chart LUBRICATION SYSTEM 5 5 Specifications Item Standard Engine Oil Grade Viscosity Capacity Level Oil Pressure Oil Pressure Switch Detect pressure Screw Oil Filter By pass Valve Openning Pressure SF SG SH or SJ class SAE40 SAE30 SAE10W 30 SAE10W 40 SAE5W 20 When filter is not removed 1 5 L 1 6 US qt When filter is removed 1 7 L 1 8 US qt except FH721V 1 8 L 1 9 Us qt FH721V Operating range grid area on dipstick 241 to 310 kPa 35 to 45 psi 98 kPa 14 2 psi PT 1 8 pipe thread 78 5 117 5 kPa 11 4 17 1 psi Oil Pump Service Limit Inner and outer rotor clearance Outer rotor outside diameter Outer rotor thickness Pump housing inside diameter Pump housing depth Pump shaft outside diameter Pump shaft bearing inside diameter Relief valve spring free length 0 2 mm 0 008 in 40 470 mm 1 5933 in 9 830 mm 0 3870 in 40 801 mm 1 6063 in 10 230 mm 0 4028 in 10 923 mm 0 4300 in
46. 531V 0 5 mm Oversize 68 48 68 50 mm 68 60 mm Cylinder 2 696 2 697 in 2 701 in FH601V Standard Cylinder 75 18 75 20 mm 75 28 mm FH641V 2 960 2 961 in 2 964 in FH680V 0 5 mm Oversize 75 68 75 70 mm 75 78 mm FH721V Cylinder 2 979 2 980 in 2 983 in Cylinder Bore Out of Round Standard 0 01 mm 0 004 in Service Limit 0 056 mm 0 0022 in 12 5 ENGINE TOP END 4 25 Cylinder Piston Cylinder Boring and Honing Always resize to exactly 0 5 mm 0 02 in over the standard bore size If this is done accurately the stock oversize rings and piston will fit perfectly and proper clearance will be maintained Resizing the cylinder bore can be done by reliable repair shop or by using a drill press and honing tool Use the stone recommended by the hone manufactures to produce correct cylinder wall finish Machine bore first the bore diameters should be shown in the table Final Boring Bore Diameter Oversize Fine Boring Bore Diameter FH451V 500V 531V FH601V 641V 680V 721V 0 50 mm 68 46 68 48 mm 75 65 75 68 mm 2 695 2 696 in 2 978 2 979 in Final Bore Diameter Oversize Final Bore Diameter FH451V 500V 531V FH601V 641V 680V 721V 68 48 68 50 mm 75 68 75 70 mm Change to a honing stone for finishing the final bore diameter should be as shown in the table Be sure the correct stone is used and the stone is not worn Clean
47. 8 CAMSHAFT CRANKSHAFT Breather The function of the breather is to create a vacuum in the crankcase which prevents oil from being forced out of the engine through the piston rings oil seals or gaskets A sealed type crankcase emission 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 intake manifold 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 and then returned back to the crankcase cover Fresh Air Blow by Gas Ss Oil To Cylinder Head CAMSHAFT CRANKSHAFT 6 9 Breather Breather Element Removal FH451V 500V 531V Remove the bolts A and breather chamber cover Remove the element A Check to see that the plate is in place under the element A Breather Element Installation FH451V 500V 531V e Apply sealant A to the mating surface of the crankcase Sealant Kawasaki Bond Silicone Sealant 56019 120 Install a new gasket and the breather chamber cover and tighten the bolts Torque Breather Chamber Cover Bolts 5
48. 9 0 6 52 in Ib Plug Bolt Engine shroud Plug Screw Engine shroud 3 4 0 35 30 in Ib Engine Top End Cylinder Head Bolts 25 2 6 19 S Valve Clearance Lock Screws 6 9 0 7 61 in Ib Connecting Rod Big End 21 2 1 15 O Cap Bolts Rocker Arm Bolts 28 2 8 20 Rocker Cover Mounting Bolts 5 9 0 6 52 in lb Exhaust Pipe Flange Nuts 15 1 5 11 Spark Plugs 22 2 2 16 1 12 GENERAL INFORMATION Torque and Locking Agent FH601V FH641V FH680V FH721V Fastener Torque Remarks Lubrication System Engine Drian Plugs Plastic 6 9 4 61 in Ib Engine Drain Plug Metal 20 14 5 Engine Drain Plug Joint Plastic 17 12 Engine Drain Plug Joint Metal 39 29 Oil Pressure Switch 9 8 87 in lb Oil Passage Plug 3 9 35 in Ib Oil Pump Cover Plate Mounting Bolts 5 9 52 in Ib Oil Filter in the text Oil Cooler Mounting Joint 44 33 Camshaft Crankshaft Crankcase Cover Bolts 25 19 0 Breather Chamber Cover Bolts 5 9 52 in Ib Electrical System Starter Coil Screws 3 4 30 in Ib Flywheel Bolt 56 41 Fan Housing Bolts 5 9 52 in Ib Screen Bolts 5 9 52 in Ib Regulator Screws 3 4 30 in Ib Ignition Coil Bolts Studs 7 8 69 in Ib Ignition Coil Bolts Bolts 5 9 52 in Ib Starter Motor Mounting Bolts 11 Recoil Starter Mounting Nuts Recoil Starter Retainier Screw Spark Plugs Apply a non permanent locking agent to the threads Apply a molybdenum disulfide lubricant grease or oil to the threads seated s
49. Commutator Runout Service Limit 0 4 mm 0 016 in e Measure the armature winding resistance Set the hand tester to the R x 1 range and measure the resistance between each segment A and all the others If the resistance it too high or even infinite the armature winding has an open circuit Replace the starter motor Armature Winding Resistance Close to 0 Q e Set the hand tester to the R x 1 range and measure the resistance between the commutator and the armature shaft B If the resistance is less than infinite the armature is shorted Replace the starter motor Commutator to Shaft Resistance ELECTRICAL SYSTEM 7 23 Starter System e Test the armature winding for shorts Place the armature on a growler A Hold a thin metal strip e g hack saw blade on top of the armature Turn on the growler and rotate the armature one complete turn If 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 hand tester to the x 1 range and measure the resistance between the positive brush es A and brush plate B If the resistance is less than infinite the positive brush is shorted to ground Replace the brush plate assembly Positive Brush to Ground Resistance Set the hand tester to the R x 1 range and measure the resistance between the negativ
50. FH451V FH500V FH531V FH601V FH641V FH680V FH721V Kawasaki 4 stroke air cooled v twin gasoline engine ervice Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Department Consumer Products amp Machinery Group Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts Kawasaki Heavy Industries Ltd 1999 2000 Third Edition 1 Nov 20 2000 LIST OF ABBREVIATIONS A ampere s ABDC after bottom dead center AC alternating current ATDC after top dead center BBDC before bottom dead center BDC bottom dead center BTDC before top dead center C degree s Celsius DC direct current F farad s F degree s Fahrenheit
51. S qt except FH721V 1 8 L 1 9 US qt FH721V NOTE O Some increase in oil consumption may be expected when a multi grade engine oil 10W 30 10W 40 5W 20 is used Check the oil level frequently Oil Filter Removal e Using a strap wrench or oil filter wrench A remove the oil filter B Special Tool Oil Filter Wrench 57001 1249 When 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 Turn the filter counterclockwise to remove it Oil Filter Installation Apply light film of engine oil to the seal A Install new filter O Turn the filter until the seal contacts mounting surface B of the engine Then turn the filter BY HAND S 3 4 turn more e Run the engine at slow idle speed 2 minutes Check for leaks around the engine Stop the engine Check the oil level see Oil Level Inspection Oil Cooler Removal e Remove the oil filter see Oil Filter Removal Unscrew the mounting joint A and remove the oil cooler Check the O ring in groove of the oil cooler for damage Replace the O ring with a new one if necessary Oil Cooler Installation Install the oil cooler with the mounting joint and tighten it Torque Oil Cooler Mounting Joint 44 4 5 kg m 33 ft lb e Install the oil filter see Oil Filter Installation lt Ambient Temperature 20C
52. TING Starter Motor Troubleshooting Guide 1 Disconnect spark plug caps from the spark plugs 2 Turn engine switch to START position and check condition Engine may be cranked in this test Do not touch any rotating parts of engine and equipment during test CAUTION If starter does not stop by engine switch OFF disconnect negative lead from battery as soon as possible STARTER DOES NOT ROTATE Y Is click sound from NO Solenoid switch Faulty battery Faulty leads or connection e Melted fuse Faulty engine switch Faulty solenoid switch r Charge or replace r Repair or replace r Replace r Repair or replace r Replace e Weak battery Faulty leads or connection Solenoid to motor Faulty solenoid switch Main terminal in solenoid Faulty starter motor STARTER ROTATES BUT SLOW Charge or replace r Repair or replace H Replace r Repair or replace Main terminal in solenoid Faulty starter motor Faulty engine STARTER ROTATES BUT NOT CRANK ENGINE Does pinion mesh with ring gear Repair or replace Is battery normal and well NO gt e Weak battery Charge or replace charged YES Faulty leads or connection Solenoid to motor 9 Faulty solenoid switch Replace Repair or replace Repair or replace NO gt Worn pinion or ring gear Replace
53. ame or sparks this includes any appliance with a pilot light e Disconnect the fuel pump outlet nozzle from the tube 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 If fuel flow is none or little replace the fuel pump Check for clogged or damaged tubes and fuel filter Replace the faulty parts Fuel Filter Inspection e Visually inspect the fuel filter A If the filter is clear with no signs of dirt or other contamination it is OK and need not be replaced If the filter is dark or looks dirty replace with a new one Also check the rest of the fuel system for contamination FUEL SYSTEM 2 25 Air Cleaner Element Removal FH451V 500V 531V Pull the hooks A to outside and remove the air cleaner cover e Remove Wing Bolt A Foam Element B Paper Element C Element Removal FH601V 641V 680V 721V e Remove Air Cleaner Case Nut Air Cleaner Case Wing Nut A Foam Element B Paper Element C Element Installation Install the element correctly on the air cleaner body Be sure the paper element is in place in the air cleaner body e Be sure the foam element is in place on the paper element body Element Cleaning and Inspection FH451V 500V 531V NOTE O In dusty areas the elements should be cleaned more frequently than the recommended intervals AWARNING
54. amond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE Do 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 operate the cutter B with one hand C Do not apply too much force to the diamond portion NOTE Prior 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 a thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter represent the following 1 Cutter number selected from 1 to 12 30 Cutter angle A 37 5 Cutter diameter of cutter B KS8B Manufactured lot number Operating Procedures Clean the seat area carefully Recondition the valve seats with the valve seat cutters 45 30 and lap the valves Check the seats for good contact all the way around with machinist s dye Measure the seat width A If it is more than the STD width the seating surface should be refaced e f the valve seating pattern is not correct repair the seat e Coat the seat with machinist s dye e Fit a 45 cutter A to the holder and slide it into the valve guide
55. anel assembly A while unhooking the governor spring B end loop at the panel bracket e Clear the choke link rod lower end C from the choke lever Control Panel Assembly Installation e Before installing the control panel assembly check to see that the choke lever A and engine speed control lever B move smoothly in all directions If any part is worn or damaged replace the control panel assembly e After installation adjust the low idle speeds and high idle speeds to the specifications see Low Idle Speed and High Idle Speed adjustment Governor Arm Removal e Remove Control Panel Assembly Loosen the clamp nut A and take off the governor arm B e Unhooking the throttle link rod spring C end loop and clear the throttle link rod lower end D 2 10 FUEL SYSTEM Governor Link Mechanism Governor Arm Installation Install the governor arm A onto the governor shaft temporarily Be sure the link spring around the throttle link rod is and that it pulls the governor arm and throttle lever E each other e Loosen the clamp nut F on the governor arm enough to move the governor shaft Turn the top end of the governor arm counterclockwise to fully open the carburetor G throttle valve and hold it there Turn the governor shaft counterclockwise fully turn the shaft to end of its travel Tighten the clamp nut Torque Governor Arm Clamp Nut 7 8 N m
56. ap as shown A Arrow Match Marks B Top ring End Gap Upper Steel Rail End Gap C 30 45 Second Ring End Gap Lower Steel Rail End Gap e Apply engine oil to the piston pins Assemble the pistons onto the connecting rods as follow No 1 cyl Piston align the arrow match mark on the piston head with opposite the raised letters K Mark on the connecting rod No 2 cyl piston align the arrow match mark on the piston head with K Mark on the connecting rod A No 1 Cyl Piston No 2 Cyl Piston Arrow Match Marks D K Mark Opposite Mark When installing a piston pin snap ring compress it only enough to install it and no more Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the notch B in the edge of the piston pin hole CAUTION Do not reuse the snap rings as removal weakens and deforms them They could fall out and score the cylinder wall ENGINE TOP END 4 21 Cylinder Piston e Apply engine oil to the piston skirt and the cylinder bore Using the piston ring compressor grip A and the belt lightly tap the top of the piston with a plastic mallet C to insert the piston and connecting rod into the cylinder Special Tool Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 57001 1097 e Insert the piston and connecting rod so that the arrow match mark A on the
57. ark plugs The system consists of the following Inductive Ignition Assemblies Permanent Magnet Flywheel Spark Plugs Stop Switch Co Core Lamination D1 Diode L1 Primary Coil L2 Secondary Coil Q1 Transistor B Base C Collector E Emitter R1 Control Resistor TS1 Trigger Sensor SP Spark Plug SW Stop Switch Flywheel M Magnet CW Rotation N North Pole S South Pole 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 of 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 to emitter to ground The trigger sensor TS1 senses the optimum time peak current to remove the base drive from the transistor Q1 This abrupt turning off 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 reac
58. ase to the pipe at the back of the cleaner body e Tighten the holder plate nuts and cleaner body mounting screws Torque Holder Plate Nuts 5 9 N m 0 6 kg m 52 in Ib Cleaner Body Mounting Screws 3 4 0 35 kg m 30 in Ib Cleaner Body Installation FH601V 641V 680V 721V e Replace the intake pipe gasket with new ones e Clean the mating surfaces of the carburetor and intake pipe e Install the intake pipe and solenoid valve wire e Tighten the mounting bolts and nuts Torque Intake Pipe Mounting Bolts and Nuts 5 9 N m 0 6 kg m 52 in Ib e Install the sleeve on the intake pipe e Press in the sleeve A to the intake pipe B fixing the groove C to the projection D as following e Connect the breather tube to the pipe at the intake pipe and clip it with a clamp 2 28 FUEL SYSTEM Air Cleaner Housing Case and Body Inspection Clean the housing with detergent and water and dry thoroughly Check the housing for deformation or other damage The housing must seal well and permit only filtered air to reach the carburetor If the housing is damaged it must be replaced Check that no foreign material is obstructing the air passage COOLING SYSTEM 3 1 Cooling System Table of Contents Exploded VIeWw 5 edam atto Matai Sane ee e 3 2 Cooling 3 4 Cooling Fan Removal an a eae 3 4 Cooling Fart Installati
59. at several points on both side Use a dial bore gauge If the inside diameter is more than the service limit replace the piston Piston Pin Hole Inside Diameter Service Limit 16 08 mm 0 633 in 4 24 ENGINE TOP END Cylinder Piston Measure the inside diameter A of the small end of the connecting rod at several points Use a dial bore gauge If the inside diameter is more than the service limit replace the connecting rod Connecting Rod Small End Inside Diameter Service Limit 16 05 mm 0 632 in Piston Diameter Measure the outside diameter of the piston 12 5 mm 0 9 in up from the bottom of the piston at a right angle to the direction of the piston pin hole If the measurement is less than the service limit replace the piston Piston Diameter Model Service Limit FH451V FH500V FH531V 67 79 mm 2 669 in FH601V FH641V FH680V FH721V 74 99 mm 2 952 in Cylinder Inside Diameter Clean and measure the cylinder inside diameter Use dial bore gauge to measure front to back and side to side at the points shown figure If any of the cylinder bore measurements is greater than the service limit the cylinder must be bored to the next oversize and then honed see Cylinder Boring and Honing Cylinder Inside Diameter Model Item standard Service Limit FH451V Standard Cylinder 67 98 68 00 mm 68 10 mm 500 2 676 2 677 2 681 in FH
60. below the crankcase surface C Governor Shaft Installation Apply engine oil to the governor shaft Insert the governor shaft into the crankcase Install the governor shaft plate A to the shaft as shown Torque Governor Shaft Plate Screws 2 0 0 20 kg m 17 in Ib Check that the governor shaft moves freely in its operating range NOTE O If the oil seal is removed oil seal is put on after shaft is installed 2 12 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 jet The resulting 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 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 t
61. between screen A and fan housing If clearance is less than 1 mm add proper number of spacer C between screen and bracket comp D to adjust clearance G 1 3 mm F Screws Clearance 1 3 mm ENGINE TOP END 4 1 Engine Top End Table of Contents Exploded Vi6W i 42 2 4 2 Specifications decret preste e E esis pen esae dee 4 6 G lind r Head 4 4 9 Compression Measurement 5 4 i haa epp deo e dt ie ie te edu eee 4 9 Cylinder Head Assembly 4 10 Cylinder Head Assembly 4 10 Push Rod Removal dee ett eg anc rina ETE Pee as De deren 4 11 Push Rod Installation ia iv eter 4 11 P sh Rod Inspection cii e e cnt eh re E eh eerte teu 4 12 Valve Mechanism Removal Installation essen nennen nennen nenne nnne nennen nnns 4 12 Cleaning arid Irispection x o degemenei MER eerie ede eei dre rives 4 13 MalV6S die DRE UU ERE ERE OE RECTORIBUS 4 14 Valve Clearance Inspection ia nai kai Ahn ela dete eO a ME oak nats 4 14 Valve 25 eter 4 14 Valve Seat Inspection o pie RU OUR e edad efie
62. ce Spark Plug Plug gap 14 1 V DC in the text 28 4 V AC 3000 rpm in the text in the text 8 to 11 CHAMPION RCJ8Y 0 75 mm 0 030 in BPR4ES 0 75 mm 0 030 in 15 V DC 26V AC 3000 rpm Electric Starter System Starter motor Carbon brush length with spring boss groove depth Commutator approx Commutator diameter Commutator runout Special Tool 12 7 mm 0 500 in 2 0 mm 0 078 in 31 7 mm 1 250 in Hand Tester 57001 1394 6 4 mm 0 250 in 0 9 mm 0 035 in 81 1 mm 1 225 in 0 4 mm 0 016 in ELECTRICAL SYSTEM 7 7 Wiring Diagram FH451V FH500V FH531V Note Portion surrounded 2242 shows KHI procurement parts Spark Plugs S gos Starter Flywheel Crank 5 b 4 5 6 LIA Regulator Option Oil Pressure Switch Oil Lamp Solenoid Switch START EXE eda 7 8 ELECTRICAL SYSTEM Wiring Diagram FH451V FH500V FH531V Note Portion surrounded by 2222 shows procurement parts Spark Plugs y To Electric Clutch 2VDC Engine stop Switch ELECTRICAL SYSTEM 7 9 Wiring Diagram FH451V FH500V FH531V Note Portion surrounded by zzz shows KHI procurement parts Spark Plugs Flywheel Engine Stop Switch 7 10 ELECTRICAL SYSTEM Wiring Diagram FH601V FH641V
63. cessively backed off carbu retor pilot screw Adjust Adjust Open choke Adjust Worn piston piston rings e Stuck piston e Worn cylinder bore e insufficient cyl head tightness Faulty valve seat contact Plunge up of valve e Wrong valve timing e Broken valve spring e Stuck valve Plugged oil ring groove High oi level e Worn valve stems and valve guide e Oil leakage along governor shaft e Oil leakage from oil seal Oil leakage from mounting surface e Oil leakage from drain plug Clogged breather valve Drain back hole in breather chamber plugged lncorrect oil viscosity Replace Clean or replace Bore or replace Retighten Lap Adjust valve clearance Adjust Replace Clean or replace Clean Adjust Replace Replace Replace Replace gasket Retighten or replace gasket Clean Clean Correct e Worn piston rings e Stuck piston rings Worn cylinder bore e Broken piston ring Replace Clean or replace Bore or replace Replace Ge Loose carb or intake manifold e Loose cyl head or leaking head gasket e Burned or sticking intake valve Faulty ignition coil e Carb not properly adjusted Stale fuel GQ Excessive carbon deposit in engine Ge Excessive engine load Ge Engine overheating Faulty ignition coil Tighten Tighten Replace Replace Adjust Change Clean Adjust See engine loss power Replace 8 6 TROUBLESHOO
64. e brush es A and brush plate B If the meter does not read close to 0 the brush plate is faulty Replace the brush plate assembly Negative Brush to Ground Resistance Close to 0 2 Pinion Clutch Inspection e Turn the pinion gear by hand The pinion gear should turn clockwise freely If the pinion clutch does not operate as it should or if it makes noise replace the pinion clutch 7 24 ELECTRICAL SYSTEM Starter System Recoil Starter Removal e Remove Recoil Starter Mounting Nuts A Recoil Starter B Recoil Starter Installation e Install the recoil starter and tighten the mounting nuts Torque Recoil Starter Mounting Nuts 5 9 N m 0 6 kg m 52 in Ib Recoil Starter Disassembly Remove the recoil starter see Recoil Starter Removal Pull the handle A out 30 cm 1 ft and clamp the with the clip C so it can not wind back onto the reel D e Pry the knot E out of the handle and untie it e Remove the handle from the rope AWARNING Wear gloves to avoid injury for the remaining steps While carefully holding the reel A and case remove the clip e Unwind the spring tension slowly NOTE Do not wedge the rope between the reel and case e Remove Screw A Washer B Retainer C Center Spring D Washer E EAE Pawls F 0 9 3 6 Return Springs ELECTRICAL SYSTEM 7 25 Starter System
65. e hard to start Remove spark plug and check spark by cranking engine while having the plug touched against engine block AWARNING Keep the plug as far away as possible from the plug hole To avoid an electric shock do not hold the plug itself Make sure to hold the plug cap Are spark produced when spark plug is replaced YES ial Y Are sparks produced YES when ignition coil is replaced Is compression sufficient Check carburetor Make starting attempts a number of times and then remove spark plug and observe electrodes Are they wet NO YES gt Faulty spark plug Replace Faulty ignition coil Replace NO lncorrect air gap Correct Faulty flywheel Replace No fuel in the tank of dust or air into fuel pipe or filter Plugged air hole in tank cap and fuel pump Plugged fuel line Excessive use of choke Plugged air cleaner Too high fuel level in float bowl Y eCheck for fuel line e Check for plugged air passage e Check float level Check carb setting plugged Worn piston piston rings e Stuck piston rings e Worn cyl bore lnsufficient cyl head tightening Faulty contact valve seat Plunge up by valve Warped cyl head Broken valve spring Stuck valve of B
66. e regulated output voltage at various engine speeds O Connect 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 the output voltage is much higher than the specification the regulator is defective or the regulator leads are loose or open If 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 VDC ELECTRICAL SYSTEM 7 15 Charging Ignition System Stator Coil Resistance e Disconnect the connector A e Measure the stator coil resistance Electric Starter Model O Connect an ohmmeter between stator pins B Stator Coil Resistance Electric Starter Model 0 01 to 0 1 Q Recoil Starter Model with Electric Clutch O Connect an ohmmeter between stator pin and engine body Stator Coil Resistance Recoil Starter Model with Electric Clutch 4 4 to 15 2 If the meter does not read as specified replace the stator coil If the coil has normal resistance but the voltage inspection showed the alternator to be defective the flywheel magnets have probably weakened and the flywheel must be replaced e Check for continuity between each stator pin and ground There should be no continui
67. ections at right angles at four different positions on the stem If any single measurement is less than the service limit replace the valve Valve Stem Diameter Service Limit Intake 5 95 mm 0 234 in Exhaust 5 93 mm 0 233 in Valve Guide Inside Diameter e Use a small bore gauge or a micrometer to measure the inside diameter A of the valve guide B a three places down the length of the guide If the measurement is more than the service limit replace the cylinder head with a new one Valve Guide Inside Diameter Service Limit Intake Exhaust 6 08 mm 0 239 in Valve Spring Inspection e Inspect the valve spring for pitting cracks rusting and burns Replace the spring if necessary Measure the free length A of the spring If the measurement is less than the service limit replace the spring Valve Spring Free Length Service Limit 31 0 mm 1 22 in ENGINE TOP END 4 19 Cylinder Piston Piston Removal Split the crankcase see Camshaft Crankshaft chapter e Remove the camshaft see Camshaft Crankshaft chapter Turn the crankshaft to expose the connecting rod cap bolts A Remove the bolts and take off the connecting rod caps NOTE Note the position of the connecting rod caps for reinstalling the caps e Push the connecting rod end into the cylinder and pull the piston and connecting rod out of the cylinder CAUTION
68. ed et diee legio e b per ere iie axe exe ote de 7 24 Recoil Starter Disassembly ss ru oic iei trot Ee Wie nep 7 24 Recoil St rter Assermibly ER akin ee rnt nh a AL Ie Rp EAE CREER e 7 25 7 2 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 7 3 Exploded View FH451V FH500V FH531V T1 8 9 N m 0 40 kg m 35 in Ib T2 5 9 N m 0 60 52 in Ib T3 7 8 N m 0 80 kg m 69 in Ib T5 56 N m 5 7 kg m 41 ft lb T6 22 N m 2 2 kg m 16 ft Ib FH601V FH641V FH680V FH721V T1 8 9 N m 0 40 kg m 35 T2 5 9 N m 0 60 52 in Ib T3 7 8 N m 0 80 69 in Ib T5 56 N m 5 7 kg m 41 ft lb T6 22 N m 2 2 kg m 16 ft Ib G Apply grease 7 4 ELECTRICAL SYSTEM Exploded View FH451V FH500V FH531V ELECTRICAL SYSTEM 7 5 Exploded View FH451V FH500V FH531V T2 5 9 N m 0 60 kg m 52 in Ib T3 7 8 N m 0 80 kg m 69 in Ib T4 17 1 7 12 ft lb G Apply grease 7 6 ELECTRICAL SYSTEM Specifications Standard 451 500 531V 601 641 680V 721 Service Limit Charging System Regulated output voltage Alternator stator coil resistance Unregulated stator output Regulator resistance Ignition System Ignition coil Primary winding resistance Secondary winding resis tan
69. either lobe replace the camshaft Cam Lobe Height Model Service Limit FH451V 500V 531V IN 29 131 mm 1 1469 in EX 29 131 mm 1 1469 in FH601V 641V 680V 721V IN 29 621 mm 1 166 in EX 29 621 mm 1 166 in 6 12 CAMSHAFT CRANKSHAFT Camshaft Tappet Measure both camshaft journals at several points around the journal circumference the journal diameter is less than the service limit replace the camshaft PTO Side Camshaft Journal Diameter Service Limit 15 985 mm 0 6293 in Flywheel Side Camshaft Journal Diameter Service Limit 15 985 mm 0 6293 in e Measure the inside diameter A of the camshaft bearing on the crankcase at several points This bearing is not replaceable Replace the crankcase if the inside diameter is more than the service limit Camshaft Bearing Inside Diameter Crankcase Service Limit 16 136 mm 0 6352 in e Measure the inside diameter A of the camshaft bearing on the crankcase cover at several points This bearing is not replaceable Replace the crankcase cover if the inside diameter is more than the service limit Camshaft Bearing Inside Diameter Crankcase Cover Service Limit 16 136 mm 0 6352 in CAMSHAFT CRANKSHAFT 6 13 Crankshaft Connecting Rod Connecting Rod Removal e Remove Piston see Engine Top End Chapter Connecting Rod Installation Install Piston see Engine Top End chapter Crankshaft Removal Set the engi
70. el tube at the fuel inlet joint A of the carburetor e Disconnect the solenoid valve lead terminal and remove the earth terminal Electric Starter Model Unhook the throttle link spring at the throttle shaft lever top end with a long nose plier Unhook the throttle and choke link rods E at the top ends of their arms while pull off the carburetor FH451V 500V 531 Unhook the throttle link spring at the link clip F with a long nose plier e Unhook the link clip F and remove the throttle D and choke link rods at the ends of their arms while pull off the carburetor FH601V 641V 680V 721 Carburetor Installation e Clean the mating surfaces of the carburetor and intake manifold and fit the new gaskets Take care not to bend the throttle and choke link rods during installation Make sure the link spring around the throttle link rod is inplace and that it pulls the governor arm and carburetor throttle shaft lever toward each other e Be sure the fuel tube clip ends A face horizontal direction AWARNING Improper installation of the fuel intake hose clamp can result in gasoline leakage and potential fire hazard Be sure the clip ends of the hose clamp face in a horizontal direction In a vertical position see illustration the clip ends A can come into contact with the intake pipe and become loose Idle Speed Good Bad FUEL SYSTEM 2 17
71. en the cylinder cools NOTE Do not use gasoline kerosene or commercial solvent to clean the cylinder bore These fluids only wash all the oil from the cylinder wall They do not remove the metal particles produced during honing Clean the cylinder thoroughly Use soap warm water and clean rags Clean the cylinder wall for white glove inspection A clean white rag should not show soil from the cylinder wall Dry the cylinder and coat with a engine oil CAUTION The cylinder must be thoroughly cleaned after honing to eliminate all grit ENGINE TOP END 4 27 Muffler Exhaust Pipe Installation Muffler Exhaust Pipe Removal Loosen the clamp nut A Remove the bolt on the muffler bracket and take off the muffler e Unscrew the exhaust pipe flange nuts A and remove the exhaust pipe B with pipe cover C Use a penetrating oil if necessary to break threads loose e Remove the gaskets e Unscrew the hook nut D separate the exhaust pipe and pipe cover e Do not use unnecessary force on the exhaust pipes when removing the muffler assembly or they could become damaged or distored Muffler Exhaust Pipe Installation e Clean the exhaust pipe flanges to the exhaust port gasket surfaces and install a new gaskets each time the muffler installed e Install the gasket e To prevent mis threading finger tight the flange nuts first Next tighten the hook nut e Tighten the nuts T
72. ene and 7596 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 If a cracks is present in the cylinder head replace it e Inspect the mating surface for burrs and nicks e Clean and inspect the rocker arm where it touches the push rod and valve stem If the contact points A are worn or damaged replace the rocker arm 4 14 ENGINE TOP END Valves Valve Clearance Inspection NOTE O Valve clearance must be checked when the engine is cold at room temperature Remove the rocker cover see Cylinder Head Removal e Place the piston at top dead center TDC of the compression stroke turning the crankshaft clockwise facing the flywheel No 1 Cylinder The left projection A on the flywheel is faced with the right leg on the 1 ignition coil C as shown Check the intake and exhaust valves are closed completely if not turn the flywheel one turn 360 clockwise and face the left projection with the right leg again No 2 Cylinder O The left projection A on the flywheel is faced with the right leg B on the 2 ignition coil C as shown Follow No 1 Cylinder alignment Then check the valve clearance Using a thickness gauge A measure the valve clearance between the rocker arm B and the valve stem end If the valve clearance
73. er Jet FUEL SYSTEM 2 13 Carburetor Fuel Shut Off Solenoid Valve Electric Starter Model 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 valve seat 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 Disconnect all possible external loads from the engine Start the engine and warm it up thoroughly Always keep your hands clear of the moving parts Move the throttle lever on dash to the idle position and 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 specified speed FH451V 500V 531V e Adjust the low idle speed screw C with Phillips Screwedriver D until the engine idles at specified speed FH601V 641V 680V 721V Idle Speed Carburetor idle rpm 1450 rpm e Release the throttle lever and adjust the low idle speed set screw B on the control plate to obtain the specified governed low idle speed Low Idle Speed Governed idle rpm 1550 rpm High Idle Speed Adjustment NOTE O High idle speed adjustment should be made after the idle speed adjustment is p
74. erformed CAUTION Do not adjust high idle speed with the air cleaner removed e Start and warm up the engine thoroughly 2 14 FUEL SYSTEM Carburetor AWARNING Always keep your hands clear of the moving parts Move the throttle lever at a dash to the high idle position and match the lever hole position with the panel hole by inserting 6 mm dia pin or bolt A e Loosen two M6 control panel mounting bolts B enough to move the control panel assembly e Carefully move the control panel assembly right side C up or down to obtain the specified high idle speed High Idle Speed 3600 rpm e Tighten the M6 Mounting bolts Torque Control Panel Mounting Bolts 5 9 N m 0 60 kg m 52 e Remove the 6 mm dia pin or bolt e Check the idle speed and readjust the idle speed if necessary CAUTION Be sure to make the idle and high idle speeds respectively correspond to those of the equipment High Altitude Operation At high altitude the standard carburetor air fuel mixture will be excessively rich Performance will decrease and fuel consumption will increase High altitude performance can be improved by installing a smaller diameter main jet in the carburetor and correct idle speed NOTE O The main jet high altitude kits are available if the equipment is to be used in the high altitudes The main jet numbers are stamped on ends of the main jets High Altitude Main Jet Main
75. etermining what CAUSED the failure If the failure was brought on by some other item or items they too must be repaired or replaced or the replacement part will soon fail again O Make sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc Poor wires and bad connections will affect electrical system operation O Measure coil and winding resistance when the part is cold at room temperature O Electrical Connectors Female Connectors A Male Connectors B 7 12 ELECTRICAL SYSTEM Charging Ignition System Flywheel Stator Coil Removal Remove Recoil Starter see Recoil Starter Removal Nuts A and Guard B Bolts C and Screen D Spacer E e Loosen the fan housing bolts A and remove the fan housing B e Remove Ignition Coils see Ignition Coil Removal Stud Bolts A Hold the flywheel with a suitable tool remove the flywheel bolt and washer e Using a suitable flywheel puller A remove the flywheel B CAUTION Always use flywheel puller ELECTRICAL SYSTEM 7 13 Charging Ignition System e Remove Woodruff Key A Stator Coil Lead Connector B Stator Coil Screw C Stator Coil D Flywheel Stator Coil Installation e Install the stator coil and tighten the screws Torque Stator Coil Screws 3 4 0 35 kg m 30 in Ib e Using a cleaning fluid clean off any oil or dirt on the followi
76. 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 deteriorated performance replace the damaged parts 1 4 GENERAL INFORMATION Model Identification Electric Starter Model FH500V Recoil Starter Model FH500V Cylinder Number Designation 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 GENERAL INFORMATION 1 5 Model Identification Electric Starter Model FH680V 1 6 GENERAL INFORMATION General Specifications Items FH451V FH500V FH531V FH601V FH641V FH680V FH721V Type of engine Forced air cooled vertical shaft OHV 4 stroke gasoline engine Oylinder layout 90 V Twin Bore x Stroke 68 mm x 68 mm 2 68 in x 2 68 in 75 2 mm x 76 mm 2 96 in x 2 99 in Piston displacement 494 mL 30 1 cu in 675 mL 41 19 cu in Direction of rotation Counterclockwise facing the PTO shaft Compression release Automatic compression release Low idle speed 1550 rpm Fast idle speed 3600 rpm
77. form the work efficiently and to avoid costly mistakes read the text thoroughly familiarize yourself with the procedures before starting work and then do the work carefully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may adversely affect safe operation To get the longest life out of your engine e Follow the Periodic Maintenance Chart in the Service Manual Be alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki engine parts Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual carefully Don t take shortcuts e Remember to keep complete records of maintenance and repair with dates and any new parts installed How to Use This Manual In preparing this manual we divided the product into its major systems These systems became the manual s chapters 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 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 mainte
78. ft foot feet g gram s h hour s L liter s Ib m min N Pa PS psi rpm TDC TIR pound s meter s minute s newton s pascal s horsepower pound s per square inch revolution revolution s per minute top dead center total indicator reading volt s watt s ohm s Read OWNER S MANUAL before operating EMISSION CONTROL INFORMATION To protect the environment in which we 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 through 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 optimum fuel economy with a suitable air cleaner and exhaust system TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED Federal la
79. ghten the mounting bolts Torque Intake Manifold Mounting Bolts 5 9 N m 0 6 kg m 52 in Ib e Install and tighten the band A around the manifold B and wirelead C and or harness D O Position the wire and or harness on top of the manifold as shown e Cut excess the band off e Install the other removed parts FUEL SYSTEM 2 23 Intake Manifold Intake Manifold Inspection Inspect the intake manifold for cracks or porous casting e Cracks not visible to the eye may be detected by coating the suspected area with mixture of 25 kerosene and 75 light engine oil 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 If a crack is present in the intake manifold replace it Inspect the gasket surfaces for burns and nicks 2 24 FUEL SYSTEM Fuel Pump Fuel Filter The fuel pump cannot be disassembled if any damage for the pump is noticed replace it with a new one Fuel Pump Inspection Check the vent hole A and filter for plugging or clogging If vent hole and filter are plugged or clogged remove the foreign matter from them Fuel Flow Test AWARNING Gasoline is extremely flammable and can be explosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of fl
80. he 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 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 Main Fuel Flow Pilot Fuel Flow Main System Fuel and Air Supply Air Cleaner Fuel Main Engin Tank Jet Float Main Air Carburetor Chamber Passage Main Jet Pilot System Fuel and Air Suppiy Fuei Float Main Tank Chamb
81. he pump parts assembly A Pin Pump Gear Mounting Bolts Outer Rotor Inner Rotor Pump Shaft G Relief Valve Ball Spring Pump Cover Plate J 6 mm DIA Hole Oil Pump Relief Valve Installation Fill the rotor housing with engine oil for initial lubrication Install the relief valve ball and spring in position then install the pump parts assembly in the crankcase cover NOTE O When Installing the pump parts assembly align the 6 mm DIA hole A on the cover plate with center of the relief valve Install the mounting bolts and tighten them Torque Oil Pump Cover Plate Mounting Bolts 5 9 0 6 kg m 52 in Ib Oil Pump Relief Valve Inspection e Remove the oil pump see Oil Pump Relief Valve Removal e Visually inspect the pump gear outer and inner rotor and cover plate If there is any damage or uneven wear replace them O Check the clearance A between the inner and outer rotor with a feeler gauge Measure the clearance between the high point of the inner rotor and the high point of the outer rotor If the measurement exceed the service limit replace the rotors as a set 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 If the rotor diameter is less than the service limit replace both the inner and outer rotor Outer Rotor Outside Diameter Service
82. hes 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 protecting the internal components of the ignition With the stop switch SW in the closed position primary voltage is routed to ground preventing ignition operation 7 18 ELECTRICAL SYSTEM Charging Ignition System Ignition Coil Removal e Remove Fan Housing see Flywheel Stator Coil Removal Spark Plug Cap A Stop Switch Lead Connector B Bolts C Ignition Coil D Ignition Coil Installation e Install ignition coil on crankcase so that the stop switch lead connector B face the screen and tighten bolt 1 first then tighten bolt 2 While tightening bolts adjust the air gap A 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 830P701881 C Torque Ignition Coil Bolts Stud Bolt 7 8 N m 0 80 kg m 69 in Ib Ignition Coil Bolts Flanged Bolt 5 9 N m 0 6 kg m 52 in Ib NOTE O Above procedure must be used to insure proper coil air gap is not too large ELECTRICAL SYSTEM 7 19 Charging Ignition System Ignition Coil Inspection e Remo
83. illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require specified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents Before Servicing iin ee eee eee el Sie ee ee et 1 2 Model deritifiCatioriz rr eer RI a RE Ep EURO 1 4 General Specifications totae teme e deo nee Mee pete REM 1 6 Periodic Maintenance Chart sa oa i oat ete dete a eut quaeve bende 1 7 Lockirig AQgent e RS ae rege fe dte qt RI ees 1 9 Special TOONS REN 1 13 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 me
84. in Valve stem diameter Intake 5 95 mm 0 0234 in Exhaust 5 93 mm 0 0233 in Valve guide inside diameter Intake Exhaust 6 08 mm 0 239 Valve spring free length Intake Exhaust 31 0 mm 1 22 in Rocker arm push rod rounout Intake Exhaust 0 5 mm 0 02 in Cylinder Piston Piston diameter 67 79 mm 2 669 in Piston ring groove clearance Top 0 15 mm 0 006 in Second 0 12 mm 0 005 in Piston ring thickness Top Second 1 40 mm 0 055 in Piston ring end gap Top 0 70 mm 0 028 in Second 0 78 mm 0 031 in Oil 1 05 mm 0 041 in Piston pin outside diameter 15 96 mm 0 628 in Piston pin hole inside diameter 16 08 mm 0 633 in Connecting rod small end inside diameter 16 05 mm 0 632 in Cylinder inside diameter Standard Cylinder 68 10 mm 2 681 in 0 50 mm Oversize 68 60 mm 2 701 in Cylinder bore out round 0 056 mm 0 0022 in Standard 451 FH500V FH531V Intake Exhaust 0 075 0 125 mm 0 003 0 005 in Intake Exhaust 45 0 6 0 9 mm 0 024 0 035 in 6 00 6 012 mm 0 2362 0 2367 in Valve clearance Valve seating surface angle Valve seating surface width Intake Exhaust Valves guide inside diameter Intake Exhaust Cylinder bore diamter standard cylinder 68 00 67 98 mm 2 677 2 676 in 68 50 68 48 mm 2 697 2 696 in Standard cylinder 0 50 mm Over size ENGINE TOP END 4 7 Specifications Item Service Limit 601 FH641V FH680V
85. is incorrect adjust it Valve Clearance when cold Intake Exhaust 0 075 0 125 mm 0 003 0 005 in Valve Clearance Adjustment Since valve repairs change the valve clearance adjust the valve clearance to the specification e Assemble the cylinder head and install the cylinder head assembly on the block see Cylinder Head Installation Turn the crankshaft proper direction until the piston is at TDC of the compression stroke described above Loosen the lock screws A and valve clearance adjusting nuts Insert 0 07 mm 0 01 thiclntrakness gauge between the rocker arm and valve stem and tighten the adjusting nut until the thickness gauge begin to bind between the rocker arm and valve stem end Use a sweeping motion with the thickness gauge while making this adjustment Valve Clearance when cold Intake Exhaust 0 075 0 125 mm 0 003 0 005 in Holding the adjusting Nut with a spanner tighten the lock screw to the specified torque Torque Valve Clearance Lock screws 6 9 N m 0 70 kg m 61 in Ib Do not overtighten Remeasure any clearance that was adjusted Readjust if necessary ENGINE TOP END 4 15 Valves Valve Seat Inspection e Remove the valve see Valve Mechanism Removal Installation Inspect the valve seats for damage If the seats are warped or distorted beyond reconditioning replace amp the cylinder head e Pitted or worn valve
86. iston pin and at least 100 mm long and insert the arbor through the connecting rod small end O On a surface plate set the big end arbor on V blocks O With the connecting rod held vertically use a height gauge to measure the difference in the height of the small end arbor above the surface plate over a 100 mm length to determine the amount of connecting rod bend If connecting rod bend exceeds the service limit the connecting rod must be replaced Connecting Rod Bend Service Limit 0 15 100 mm 0 006 3 94 in 6 14 CAMSHAFT CRANKSHAFT Crankshaft Connecting Rod Measure connection rod twist O With the big end arbor still on the V blocks hold the connection rod horizontally and measure the amount that the small end arbor varies from being parallel with the surface plate over a 100 mm length of the arbor to determine the amount of connecting rod twist If connection rod twist exceeds the service limit the connecting rod must be replaced Connecting Rod Twist Service Limit 0 15 100 mm 0 006 3 94 in Connecting Rod Big End Crankpin Width Wear Measure the connecting rod big end width A with a micrometer or dial caliper If the measurement is less than the service limit replace the connecting rod Connecting Rod Big End Width Model Service Limit FH451V 500V 531V 18 80 mm 0 74 in FH601V 641V 680V 721V 19 90 mm 0 783 in Measure the crankpin width A with a dial caliper
87. l fall between the piston and cylinder and damage the crankshaft bearings e Scrape the carbon off A the piston head e Use the scraping tools carefully Do not gouge the piston head To avoid gouging use scrapers that are made of a material that will not cause damage 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 Clean the piston see Piston Cleaning e Visually inspect the piston rings and ring grooves If the piston rings are worn unevenly or damaged replace them If the ring grooves are worn unevenly or damaged replace both the piston and piston rings 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 If the piston ring groove clearance is greater than the specified value replace the piston Piston Ring Groove Clearance Service Limit FH451V FH500V FH531V FH601V FH641V FH680V FH721V Top 0 15 mm 0 006 in 0 18 mm 0 007 in Second 0 12 mm 0 005 in 0 16 mm 0 006 in NOTE O The oil ring is a three piece assembled ring Difficult to measure the ring groove clearance and thickness visually inspect only
88. l in crankcase Worn piston piston rings Worn cylinder bore Clean Clean Adjust Adjust level Replace Bore or replace See Engine Starts Hard gapped incorrectly gt e Spark plug fouled pitted or Replace or adjust Entry of dust or water into fuel Clean pipe or fuel filter Air or vapour lock in fuel line Clean Plugged air vent of fuel tank Clean cap Plugged air fuel passes in carb Clean Too little opening of carb pilot Correct screw Carb not properly adjusted m Adjust Carb flange leaking at gasket Tighten or replace Worn carb body and throttle shaft Replace 8 4 TROUBLESHOOTING Engine Troubleshooting Guide Problem in the governor gt governor linkage Correct system adjustment Faulty governor spring Replace Governor ass y malfunctioning Check Engine malfunctions at high speed Is revolution fluctuation of YES gt relatively large period produced when a load is applied Clean Clean Plugged air hole in tank cap Entry of dust and air into fuel filter or fuel pipe Engine malfunctions at low speed Remove spark plug and check WEAK e eFaulty plug insulation Replace spark by cranking engine while Fouled electrodes Clean having the plug touched against STRONG 4 Faulty ignition coil Replace engine block Incorrec
89. lectronic tachometer will facilitate setting idle and running speeds FH451V FH500V FH531V OPERATION INTERVAL Check or clean air intake screen Check and add engine oil Check for fuel and oil leakage Check for loose or lost nut and screw Check battery electrolyte level Clean air cleaner foam element 1 Clean air cleaner paper element 1 Clean dust and dirt from cylinder and cylinder head fins 1 Tighten nut and screws Change engine oil Clean and re gap spark plugs Change Oil filter Change air cleaner paper element 1 Check and adjust vlave clearance Clean and lap valve seating surface Clean combustion chamber 1 Service more frequently under dusty 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 1 8 GENERAL INFORMATION Periodic Maintenance Chart FH601V FH641V FH680V FH721V OPERATION INTERVAL Every 300 hr Check or clean air intake screen Check and add engine oil Check for fuel and oil leakage Check for loose or lost nut and screw Check battery electrolyte level Clean air cleaner foam element 1 Clean air cleaner paper element 1 Clean dust and dirt from cylinder and cylinder head fins 1 Tighten nut and screws Change engine oil Clean and re gap
90. lve moves smoothly up and down in the guide O Check the valve seating surface A between the valve B and valve seat C e Rocker Arm Installation O Soak the valve clearance adjusting nuts and rocker arm in the engine oil O Install the rocker arm ENGINE TOP END 4 13 Cylinder Head Cleaning and Inspection Scrape the carbon deposits from the head and exhaust port with a suitable tool A To avoid gouging use scrapers that are made a material that will not cause damage 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 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 the cylinder head A fire or explosion could result e Lay a straightedge A across the mating surface of the head at several different points and measure warp by inserting a thickness gauge B between the straightedge and head If warp exceeds the service limit repair the mating surface Replace the cylinder head if the mating surface is badly damaged Cylinder Head Warp Service Limit 0 05 mm 0 002 in 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 2596 keros
91. m 1 375 in 35 15 mm 1 384 in 35 15 mm 1 384 in 19 90 mm 0 783 in 43 1 mm 1 697 in 38 055 mm 1 498 in 37 94 mm 1 494 in 39 896 1 571 39 896 mm 1 571 40 15 mm 1 581 in 40 15 mm 1 581 in Sealant Kawasaki Bond Silicone Sealant 56019 120 CAMSHAFT CRANKSHAFT 6 5 Crankcase Crankcase Cover Hemoval e Set the engine on a clean surface while parts are being removed e Drain the oil see Lubrication System chapter e Remove Exhaust Pipe and Muffler see Engine Top End chapter Control Panel see Fuel System chapter Governor Arm see Fuel System chapter e Unscrew the mounting bolts A and remove the crankcase cover B from the crankcase O There are two knock pins on the crankcase mating surface A wooden or plastic mallet may be used to gently tap loose the crankcase cover Crankcase Cover Installation e Chip off the old gasket from the mating surfaces of the crankcase and cover e Using compressed air blow out the oil passage in the crankcase cover e With a high flash point solvent clean off the mating surfaces of the crankcase and cover and wipe dry AWARNING 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
92. mm 1 357 1 356 in Finishing Dimensional Specifications FH601V FH641V FH680V FH721V 43 0 mm MAX 1 693 in MAX D 37 95 38 05 mm 1 4941 1 4980 in The crankpin surface should be concentric and parallel to each other within 0 006 mm 0 0002 in full indicator reading e Finish the crankpin surface with a super finishing stone eal ELECTRICAL SYSTEM 7 1 Electrical System Table of Contents Exploded Vigw u diete leet eae dees 7 2 amp PR 7 6 Wiring Diagram FH451V FH500V 7 7 Wiring Diagram FH601V FH641V FH680V 7 10 dnte eh etitm Ds 7 11 Charging Ignition System 2 eite Parte bend 7 12 Flywheel Stator Coil 7 12 Flywheel Stator GCoil InstallatiQnis nc botas tot te ed deg eb eet Eck EXE 7 13 Charging System Operational 7 14 Stator Coil RESISTANCE chest einge 7 15 Unregulated Stator n iier desde re det tee tede qii aree etra doce cado ete aai 7 15 Regulator Fl roval p RR E e RUIN ens 7 15 Regulator Installatiori
93. nance operations If you want spark plug information for example 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 section 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 O This note symbol indicates points of particular in terest for more efficient and convenient operation e Indicates a procedural step or work to be done O Indicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a WARNING CAUTION or NOTE Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub step it follows In most chapters an exploded view
94. ne on a clean surface while parts are being removed Drain the oil see Lubrication System chapter Remove Flywheel see Electrical System chapter Camshaft see Camshaft Tappet Removal Connecting Rod and Piston Assembly see Engine Top End chapter Pull the crankshaft A out of the crankcase Tap gently with a wooden or plastic mallet if necessary to loosen the crankshaft Crankshaft Installation Clean up the crankshaft and crankcase thoroughly especially at the bearing contact surfaces Pack some amount of high temperature grease into the oil seal on the crankcase e Apply engine oil to the journal and bearing e Carefully insert the crankshaft flywheel end into the main bearing and oil seal in the crankcase Cleaning Inspection e After removing clean the crankshaft and connecting rods with a high flash point solvent and dry them with compressed air e Inspect the teeth of the crankshaft gear for pitting fatigue cracks burrs and evidence of improper tooth contact Replace the gear if necessary e Inspect the crankshaft and connecting rods especially at the bearing surfaces for wear scratches evidence of improper contact or other damages Replace them if necessary Connecting Rod Bend Twist e Measure connecting rod bend O Select an arbor of the same diameter as the connecting rod big end and insert the arbor through the connecting rod big end O Select an arbor of the same diameter as the p
95. ng portions and dry them with a clean cloth A Crankshaft Tapered Portion B Flywheel Tapered Portion e Fit the Woodruff key C securely in the slot in the crankshaft before installing the flywheel e Install the fan A so that two positioning bosses B fit around flywheel ignition magnet C e Install the plate D so that the notch E inserts into the slot in the flywheel e Install the screen A so that the projections B fit into the recess C of the fan e Install the pulley A or bracket so that the tabs of the plate fit into holes B in the pulley e Put the washer C as shown e Tighten the flywheel bolt D Torque Flywheel Bolt 56 N m 5 7 kg m 41 ft Ib 7 14 ELECTRICAL SYSTEM Charging Ignition System e Install the fan housing and tight the bolts Torque Fan housing Bolts 5 9 N m 0 6 kg m 52 in Ib e Install Recoil Starter see Recoil Starter Installation e Install Spacer A Screen B O Position three sets C of screen notches around the fan blades e Tighten the screen bolts D Torque Screen Bolts 5 9 N m 0 6 kg m 52 in Ib Charging System Operational Inspection e Check battery condition NOTE Always check battery condition before condemning other parts of the charging system The battery must be fully charged in order to conduct accurate charging system tests e Warm up the engine to bring the components up to their normal operating temperatures e Measur
96. ons ei 3 4 Cooling FarmiInSpection i eee orate eR A e p Pte eee ee ated 3 4 Screen Clearance Adjustmierit 3 5 3 2 COOLING SYSTEM Exploded View COOLING SYSTEM 3 3 Exploded View FH451V FH500V FH531V T1 3 9 N m 0 40 kg m 35 in Ib T2 5 9 N m 0 60 kg m 52 in Ib T3 17 1 7 kg m 12 0 ft lb T4 56 N m 5 7 kg m 41 ft lb T5 7 8 N m 0 8 kg m 69 FH601V FH641V FH680V FH721V T1 8 9 N m 0 40 kg m 35 in Ib T2 5 9 N m 0 60 52 in Ib T3 17 N m 1 7 kg m 12 0 ft lb 56 N m 5 7 kg m 41 ft lb T5 7 8 N m 0 8 kg m 69 in Ib 3 4 COOLING SYSTEM Cooling Fan Cooling Fan Removal e Refer to Flywheel Removal in Electrical System chapter Cooling Fan Installation e Refer to Flywheel Installation in Electrical System chapter Cooling Fan Inspection e Visually inspect the blades A in the cooling fan If they are any cracks warps or damaged replace the cooling fan If any mud or dust have stuck to the cooling fan clean it e Cooling fan is cleaned by washing in detergent and water CAUTION Do not clean the cooling fan in oil solvent It may be damage by oil solvent COOLING SYSTEM 3 5 Cooling Fan Screen Clearance Adjustment Check clearance
97. orque Exhaust Pipe Flange Nuts 15 N m 1 5 kg m 11 ft lb e Install the muffler e After installation thoroughly warm up the engine wait until the engine cools down and retighten the bolts and nuts Inspection e Inspect the exhaust pipe or muffler for dents cracks rust and holes If the exhaust pipe or muffler is damaged it should be replaced for best performance and least noise e Check the muffler for distortion and or loose internal components Loss of power could develop if the muffler loose the internal compo nents restricting the exhaust flow e Check for breaks in the seams and check weld at the junction of the exhaust pipes and muffler e Tap the muffler with a plastic hammer to decarbonize LUBRICATION SYSTEM 5 1 Lubrication System Table of Contents elena 5 2 Engine OibElow Charts ee reta cg bon dede en ede ee hoe 5 4 Specifications iss Ge Ae e nde ER ORE ERE E ee RR e Pee 5 5 Engine Oil Filter and 5 6 Oil Eevel InspecHon ene RU tos eee p E 5 6 Oil 5 6 Oil Filter 5 7 4 1 zh a de 5 7 Oil COolersRemMovalls zt tae vectra P
98. over Bolts 25 2 6 19 0 S Breather Chamber Cover Bolts 5 9 0 6 52 in Ib Electrical System Starter Coil Screws 3 4 0 35 30 in Ib Flywheel Bolt 56 5 7 41 Fan Housing Bolts 5 9 0 6 52 in Ib Screen Bolts 5 9 0 6 52 in Ib Regulator Screws 3 4 0 35 30 in Ib Ignition Coil Bolts Studs 7 8 0 8 69 Ignition Coil Bolts Bolts 5 9 0 6 52 in lb Starter Motor Mounting Bolts 15 1 5 11 Recoil Starter Mounting Nuts 5 9 0 6 52 in Ib Recoil Starter Retainier Screw 7 8 0 8 69 in Ib Spark Plugs 15 1 5 11 0 GENERAL INFORMATION 1 11 Torque and Locking Agent FH601V FH641V FH680V FH721V FH601V FH641V FH680V FH721V Fasteners Torque Remarks N m ft Ib Fuel System Choke Valve Screw 1 0 0 10 8 9 in Ib L Throttle Valve Screws 1 0 0 10 8 9 in Ib L Pilot Jet Main Jet Plug Main Jet 19 1 9 14 Main Nozzle Main Air Jet Pilot Air Jet Drain Screw Carburetor 2 0 0 2 18 in lb Earth lead screw Carburetor Side Fuel Shut Off Solenoid Valve Carburetor 20 2 0 15 Float Chamber Mounting 3 9 0 4 35 in Ib Screw Carburetor Governor Arm Clamp Nut 7 8 0 8 69 in Ib Governor Shaft Plate Screws 2 0 0 2 18 in lb Intake Pipe Mounting Bolts and Nuts 5 9 0 6 52 in Ib Intake Manifold Mounting Bolts 5 9 0 6 52 in Ib Cleaner Body Mounting Screws Control Panel Mounting Bolts 5 9 0 6 52 in Ib Cooling System Engine shroud Bolt M8 15 1 5 11 Engine shroud Bolts M6 5
99. park plugs proximity to the plug holes Keep the plugs as far away as possible from the plug holes e With the throttle fully open turn engine over sharply with the recoil starter several times until the compression gauge stops rising the compression is the highest reading obtainable Recoil Model Cylinder Compression MIN 390 kPa 57 psi e Using the starter motor turn the engine over with the throttle fully open until the compression gauge stops rising Electric Starter Model Cylinder Compression MIN 390 kPa 57 psi e Repeat the measurement to the other cylinder If the compression is higher than the specified value the piston rings cylinder and valves are probably in good condition If the compression is 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 Oylinder head gasket use only the proper gasket The use of a gasket of incorrect thickness will change the compression 3 Valve guides and piston rings rapid carbon accumulation in the combustion chamber may be caused by worn valve guides and or worn piston oil rings This may be indicated by white exhaust smoke If cylinder compression is lower than the MIN check the following 1 Gas leakage around the cylinder head replace the damaged gasket and check and check the cylinder head warp Condition of the valve seating Valve clearance
100. r Head Tighten the cylinder head bolts following the tightening sequence Torque Cylinder Head Bolts 25 N m 2 6 kg m 19 0 ft Ib 1 CYLINDER 2 CYLINDER CAUTION A torque wrench must be used to assure proper torque Improper tightening of the head bolts can result in warping of the cylinder head Check and adjust the valve clearance Install the gasket and rocker cover Torque Rocker Cover Mounting Bolts 5 9 N m 0 6 kg m 52 in Ib Install the other removed parts Push Rod Removal e Set each cylinder at T D C of power stroke e Remove the rocker covers see Cylinder Head Assembly Removal e Loosen the valve clearance adjusting nuts A e Move the rocker arms B to clear the push rod upper ends e Pull out the push rods NOTE Mark the push rods so they can be installed in their original position during assembly Push Rod Installation e Set each cylinder at T D C of power stroke e Install the push rods A in their original positions on each cylinder O To Install the push rod in a correct position on the tappet B insert the push rod so 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 intake and exhaust push rods on each cylinder are at lowest position on the cam lobes E if not turn the flywheel clockwise one turn 360 and reset each cylinder at T D C of power stroke in e
101. r Link 2 9 Control Panel Assembly Remowval 2 9 Control Panel Assembly Installation 2 9 Governor Arm 2 9 Governor Arm Installation 2 10 Governor Assembly Removal 2 10 Governor Assembly Installation 2 10 Governor Assembly Inspection 2 11 Governor Shaft 2 11 Governor Shaft Installation 2 11 Carburelor 5 2 cgi tere ei eee Hrafn 2 12 Fuel and Air Flow sese 2 12 Fuel Shut Off Solenoid Valve Electric Starter 2 13 Low Idle Speed Adjustment 2 13 High Idle Speed Adjustment 2 13 High Altitude 2 14 Main Jet 2 14 Fuel system Cleanliness Inspection 2 15 Carburetor Remowval sene 2 16 Carburetor 2 16 Carburetor Disassembly Assembly FH451V 500V 2 17 Carburetor Disassembly Assembly FH601V 641V 680 721V niet epus 2 18 Carb
102. r low flash point solvents to clean the carburetors CAUTION Do not use compressed air on an assembled carburetor or the floats may be crushed by the pressure Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carburetor with a cleaning solution This will prevent to damage or deterioration of the parts The carburetor body has plastic parts that cannot be removed Do not use a strong carburetor cleaning solution which could attack these parts instead use a mild high flash point clean ing solution safe for plastic parts Do not use wire or any other hard instrument to clean carbu retor parts especially jets as they may be damaged e Disassemble the carburetor e Immerse all the carburetor metal parts in a carburetor cleaning solution and clean them e Rinse the 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 2 20 FUEL SYSTEM Carburetor Carburetor Inspection Gasoline is extremely flammable and can be explosive 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
103. r or damage If the pilot screw is worn or damaged on the taper portion replace it Check the spring for weakened condition replace it if necessary Good Bad FUEL SYSTEM 2 21 Carburetor e Fuel Shut Off Solenoid Valve Test Electric Starter Model e Unscrew the fuel shut off valve and remove the valve e Connect a 12 VDC source to the solenoid as shown If the actuate solenoid plunger Needle Valve does not pop in when the Test Voltage is applied replace it NOTE If may be necessary to push the plunger slightly for the plunger to withdraw 2 22 FUEL SYSTEM Intake Manifold Intake Manifold Removal Remove Air Cleaner see Cleaner Body Removal Engine Upper Cover Cut off the band A and harness and or wire lead are released from intake manifold Unscrew the manifold mounting bolts Then lifting up the intake manifold middle A pull out the intake manifold from the carburetor B as shown Intake Manifold Installation e Replace the intake manifold gasket with new ones e Clean the mating surfaces of the cylinders and intake manifolds and fit a new gaskets A direction as shown B Distance FH451V 500V 531V 6 mm B Distance FH601V 641V 680V 721V 12 mm e Clean the mating surfaces of the carburetor and intake manifold and install the new gaskets A and insulator B sequence as shown e Install the intake manifold e Ti
104. races and balls from being dented Press a ball bearing until it stops at the stop in the hole or on the shaft 12 Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally damages seals When pressing in a seal which has manufacturer s marks press it in with the marks facing out Seals should be pressed into place using a suitable driver which contacts evenly with the side of seal until the face of the seal is even with the end of the hole 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 GENERAL INFORMATION 1 3 Before Servicing 15 Cotter Pin Replace any cotter pins that were removed with new ones as removal deforms 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 los
105. rence to running the engine with the oil level low Then at your earliest convenience change the oil completely If the oil level is FULL range F drain the excess oil by loosening the drain plug Oil Change Change the oil after first 8 hours of operation Thereafter change oil every 100 hours e Start and warm up the engine so the oil will drain easily Stop the engine e Place the engine on a level surface Place a suitable container under the engine Remove the drain plug A and drain the oil AWARNING Be careful of hot oil when drained It may be hot enough to burn you severely Check the O ring at the drain plug for damage Replace the O ring with a new one if it is damaged If the oil drain plug joint is removed tighten it Torque Oil Drain Plug Joint Plastic 17 1 7 kg m 12 0 ft lb Oil Drain Plug Joint Metal 39 4 0 kg m 29 ft lb e Install the drain plug with the O ring and tighten it Torque Oil Drain Plug Plastic 6 9 N m 0 7 kg m 61 in Ib Oil Drain Plug Metal 20 N m 2 0 kg m 14 5 ft Ib LUBRICATION SYSTEM 5 7 Engine Oil Oil Filter and Oil Cooler Remove the oil filler cap and pour in the specified type and amount of oil Engine Oil Grade SF SG SH or SJ Class Viscosity SAE40 SAE30 SAE10W 30 SAE10W 40 or SAE5W 20 Capacity When filter is not removed 1 5 L 1 6 US qt When filter is removed 1 7 L 1 8 U
106. rush springs for pitting cracks rusting and burrs Replace the spring if necessary e Inspect the springs for weakened conditions and distortion Replace the springs if necessary If the brush springs are able to press the brushes firmly into place they may be considered serviceable If they cannot replace them Armature Inspection Inspect the surface of the commutator A If is scratched or dirty polish it with a piece of very fine emery cloth B and clean out the grooves 7 22 ELECTRICAL SYSTEM Starter System e Measure the depth of the grooves between the commutator segments the grooves are shallower than the specified limit replace the armature with a new one If the grooves are only dirty clean them carefully Commutator Groove Depth Limit Less than 0 9 mm 0 035 in A Bad Segment C Good D 0 9 mm 0 035 in limit Mica Measure the commutator outside diameter A at several points If the diameter is less than the service limit replace the armature with a new one Commutator Outside Diameter Service Limit 31 1 mm 1 225 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 turn down the commutator or replace the armature with a new one
107. s stuck to it AWARNING 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 O While cleaning the screen check for any metal particles that might indicate internal engine damage Check the screen carefully for any damage holes and broken wire If the screen is damaged replace it CAMSHAFT CRANKSHAFT 6 1 Camshaft Crankshaft Table of Contents Exploded VIGW a ides esa uode ipee tanta ed ode 6 2 SpecifiCatlOns e enciende 6 4 Cre b e Ue m ehem aC 6 5 Grankcase Cover Removal nte bet dete eddie 6 5 Crankcase Cover Installation ade idee fe diete Ae 6 5 5 HE 6 6 eo M 6 7 Breather ci iso NL ea ba aM M II 6 8 Breather Element Removal 451 500V 531 6 9 Breather Element Installation FH451V 500V 531 6 9 Breather Valve Inspection FH601V 641V 680V 721V 6 9 Camshaft ES 6 10 Camshaft Tappet REmovall o eue ae tte
108. t air gap Correct 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 gt Overrich fuel in pilot system Turn in pilot screw by muffler a minor extent NO Directly and gradually open YES Plugged in carburetor interior Disassemble and throttle valve by hand Does the clean revolution drop or does engine NO stall at a certain position 15 air sucked through carburetor YES Loose flange nuts Retighten or intake manifold flanges TS eDamaged gasket Replace Y Are valve clearances of normal NO gt Compression leakage Adjust valve clearance values Wrong valve timing Correct alignment of YES timing gear marks Is alignment of timing gear marks NO Largely deviated valve timing Correct alignment of Y correct timing gear marks TROUBLESHOOTING 8 5 Engine Troubleshooting Guide Fuel consumption is excessive 15 compression sufficient Oil consumption is excessive Is compression sufficient Engine backfires YES B NO NE NO Engine knocks e High fuel level in carb float chamber including overflow High idling R P M Choke partially closed Ex
109. t 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 Name of Wire Color Red Wire Strands Yellow Red Yellow Red 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
110. t lb T3 See Engine Top End chapter FH601V FH641V FH680V FH721V T1 5 9 N m 0 6 kg m 52 T2 25 N m 2 6 kg m 19 0 ft lb T3 See Engine Top End chapter O Apply engine oil G Apply grease SS Apply silicone sealant S Follow the specific tightening sequence FH601V FH641V FH680V FH721V 1 Screw 2 Plate 3 Valve B Sealant bead on crankcase side of gasket 6 4 CAMSHAFT CRANKSHAFT Specifications tem Service Limit FH451V 500V 531V FH601V 641V 680V 721V Camshaft Tappet Cam lobe height Intake 29 131 mm 1 1469 in 29 621 mm 1 166 in Exhaust 29 131 mm 1 1469 in 29 621 mm 1 166 in Camshaft journal diameter PTO side 15 985 mm 0 6293 in Flywheel side 15 985 mm 0 6293 in Camshaft bearing inside diameter Crankcase 16 136 mm 0 6352 in Crankcase cover 16 136 mm 0 6352 in Crankshaft Connecting Rod Connecting rod bend 0 15 100 mm 0 006 3 94 Connecting rod twist 0 15 100 mm Connecting rod big end width Crankpin width Connecting rod big end inside diameter Crankpin Outside diameter Crankshaft runout PTO side Flywheel side Crankshaft journal diameter Crankcase PTO shaft bearing inside diameter Crankcase Cover Crankshaft journal bearing inside diameter Crankcase 0 006 3 94 in 18 80 mm 0 74 in 39 50 mm 1 56 in 35 055 mm 1 3801 in 34 94 mm 1 3756 in 0 05 mm 0 002 in TIR 34 90 mm 1 374 in 34 93 m
111. tal 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 4 Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench 5 Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removal of screws held
112. the cylinder at the top and bottom of the cylinder to remove burns and pieces of the base and head gasket e Anchor the cylinder block on the drill press table before honing Align the center of the cylinder bore to the press center Set the press to operate from 200 to 250 rpm Connect the drive shaft to the hone and set the stop on the drill press so the hone can only extend 20 to 25 mm 3 4 to 1 0 in above the top or below the bottom of the cylinder liner e Rotate the adjusting nut knob on the hone until the stones contact snugly against the cylinder wall at the narrowest point Do not Force Turn the stone by hand If you cannot turn it the stone is too tight Loosen the hone until it can be turned by hand e Be sure that the cylinder and hone are centered and aligned with the drive shaft and drill spindle e Pour honing oil inside of the cylinder during the honing operation Start the drill press Move the hone up and down in the cylinder approximately 20 cycles per minute Check the diameter of the cylinder bore regularly during honing using an inside micrometer 4 26 ENGINE TOP END Cylinder Piston CAUTION Stop the drill press before measuring and remove the hone from the cylinder NOTE O The finish should not be smooth but have a 40 to 60 degree crosshatch pattern Hone the cylinder until it is about 0 007 to 0 009 mm 0 0003 to 0 0004 in large to allow for shrinkage wh
113. top of the piston is facing the flywheel side B 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 Apply engine oil to the inner surface A of the connecting rod big end and caps e Install the connecting rod big end caps on their original position on each connecting rod big ends Apply a small amount of engine oil to the thread and seating surface E of the cap bolts Tighten the cap bolts Torque FH451V 500V 531V Connecting Rod Big End Cap Bolts 5 9 0 60 kg m 52 in Ib FH601V 641V 680V 721V Connecting Rod Big End Cap Bolts 21 N m 2 1 kg m 15 ft Ib e Install e Camshaft see Camshaft Crankshaft chapter e Crankcase Cover see Camshaft Crankshaft chapter Piston Cylinder Seizure e In case of seizure remove the piston e Visually inspect the cylinder and piston damage If there is only light damage smooth the position with 400 emery cloth Remove the small aluminum deposits from the cylinder with 400 emery cloth or light honing If the damage is severe the both cylinders must be bored oversize and oversized pistons installed 4 22 ENGINE TOP END Cylinder Piston Piston Cleaning Remove the piston and piston rings see Piston Removal CAUTION Never clean the piston head with the engine assembled Carbon particles wil
114. ty infinite ohm If 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 VAC 3 000 rpm If the AC voltage reading is less than the specification replace the stator Unregulated Stator Output MIN 26 VAC 3 000 rpm Regulator Removal e Remove Stator Coil Lead Connector A Regulator Screws B Regulator C Regulator Installation e Install the regulator and tighten the screws Torque Regulator Screws 3 4 N m 0 35 kg m 30 in Ib 7 16 ELECTRICAL SYSTEM Charging Ignition System Regulator Resistance Set the KAWASAKI Hand Tester selector switch to the x 100 2 position Connect the test leads to the points shown on the chart and read the resistance O There are two 2 types of Regulator on FH engines as follows with out Charging Monitor Type 3 Blades NOTE Resistance value may vary with individual meters With Charging Monitor type 5 Blades 77 1OKQ 10KQ If the resistance is not as specified replace the regulator ELECTRICAL SYSTEM 7 17 Charging Ignition System This engine ignition is controlled by a solid state ignition assembly and requires no periodic maintenance except for the sp
115. uretor 2 19 Carburetor 2 20 Fuel Shut Off Solenoid Valve Test ElectricStarter 2 21 Intake 2 22 Intake Manifold 2 22 Intake Manifold Installation 2 22 Intake Manifold 2 23 Fuel Pump Fuel 2 24 Fuel Pump 2 24 Fuel Filter 2 24 Ait Cleaner oae t a 2 25 Element Removal FH451V 500V 531V 2 25 Element Removal FH601V 641V 680V 721V 2 25 Element 2 25 Element Cleaning Inspection FH451V 500V BOI 2 25 Element Cleaning and Inspection FH601V 641 680 72 1M doriae n 2 26 Cleaner Body Removal FH451V 500V 531V 2 26 Cleaner Body Removal FH601V FH641V FH680V FH 21M mne 2 27 Cleaner Body Installation FH451V 500V 531V2 27 Cleaner Body Installation FH601V 641V 680V aba 2 27 Housing Case and Body Inspection 2 28 2 2 FUEL SYSTEM Exploded View FH451V FH500V FH531V
116. urface or washer Apply an oil to the threads seated surface or washer Tighten the fasteners following the specified sequence SS Apply silicone sealant 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 Torque mm N m kg m ft lb 4 2 0 0 2 17 5 3 4 0 35 30 in Ib 6 5 9 0 6 52 in Ib 8 15 1 5 11 GENERAL INFORMATION 1 13 Special Tools Compression Gauge 57001 221 Valve Seat Cutter Holder 26 57001 1360 Valve Seat Cutter 45 235 0 57001 1116 e Piston Ring Compression Grip 57001 1095 Valve Seat Cutter 30 33 0 57001 1199 e Piston Ring Compression Belt 267 079 57001 1097 Compression Gauge Adapter M14 x 1 25 57001 1159 Valve Seat Cutter Holder Bar 57001 1128 Valve Seat Cutter 30 30 0 57001 1120 1 14 GENERAL INFORMATION Special Tools Oil Filter Wrench 57001 1249 Kawasaki Bond Silicone Sealant 56019 120 Hand Tester 57001 1394 FUEL SYSTEM 2 1 Fuel System Table of Contents Exploded 2 2 2 8 Governo
117. urned head gasket Add Clean Clean Clean Remove the plug and turn the crankshaft without loading Clean Adjust Replace Clean or replace Bore or replace Retighten Lap Adjust valve clearance Replace Clean or replace Replace TROUBLESHOOTING 8 3 Engine Troubleshooting Guide Engine loss power Is engine overheated YES gt Crankcase low oil Adjust level or add Too much oil in crankcase Adjust level NO Excessive engine load Decrease load Carb not properly adjusted Adjust Carbon deposit in combustion Clean chamber Clogging of cooling system Clean Damaged cooling fan Replase Is the ignition spark NO e Wrong spark plug Replace normal Faulty ignition coil Replace YES Is lubricationg condition normal YES Is unusual smoke emitted YES out of muffler NO Is compression sufficient NO Engine runs erratically Problem in the fuel system lack of fuel Incorrect air gap Adjust gap NO e Too much or too little oil Correct crankcase Excessively contaminated lub Change ricating oil Defective oil filter Replace Faulty relief valve Replace Faulty oil pump Replace Clogging oil system Clean Plugged air cleaner Carbon deposit in exhaust hole and muffler Carb not properly adjusted Too much oi
118. ve the ignition coils see Ignition Coil Removal Measure the winding resistance as follows Set the hand tester to the x 1 range Special Tool Hand Tester 57001 1394 O Make the measurements shown in the table Ignition Coil Winding Resistance BSESENEN DN CAUTION Use only Tester 57001 1394 with new battery at room tempera ture 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 If the tester does not read as specified replace the coil Spark Plug Cleaning and Inspection e Carefully pull the plug cap from the spark plug and remove the spark plug If the plug is oily or has carbon built up on it clean the plug using a high flash point solvent and a wire brush or other suitable tool If the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug or its equivalent A Insulator B Center Electrode C Plug Gap D Side Electrode Spark Plug Gap Inspection e Measure the gap with a wire type thickness gauge If the gap is incorrect carefully bend the side electrode with a suitable tool to obtain the correct gap Spark Plug Gap Model Plug Gap Standard FH451V 500V 531V 0 75 mm 0 030 in FH601V 641V 680V 721V 0 75 mm 0 030 in
119. w 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 Carburetor and internal parts Spark plugs Magneto or electronic ignition system Fuel filter element Air cleaner elements Crankcase Cylinder heads Breather chamber and internal parts Intake 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 information to make it useful to the owner who desires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily Whenever the owner has insufficient experience or doubts as to his ability to do the work all adjustments maintenance and repair should be carried out only by qualified mechanics In order to per

Kawasaki FH641V Service Manual

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