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Kawasaki Engine Service Manual

1. t 3 14 F uel and Alr EIOW lan ree iet a dr e ri ae dad a d ar pr 3 14 Fuel Shut Off Solenoid Valve 3 17 Low He Re E EE 3 17 High Idle Speed Adjustment e Rt tet tt 3 17 High Al t de ODerellQDla EE 3 17 Main Jet Replacement 000000010 enn enn nn 3 18 Fuel System Cleanliness Inspection 4 3 19 Inlet Pipe Removal 3 20 Tnstallation 22 dese bess 3 20 Carburetor Removals 3 21 Carburetor Installation re ciet rr 3 23 Carburetor Disassembly ASSOMiD ly rac ec dese euet Ee coe 3 25 Carburetor Cleanin EE 3 28 Carburetor Inspection eee tee teta teet 3 29 Fuel Shut Off Solenoid Valve Test 3 30 ele DEET 3 31 Inlet Manifold Removal 3 31 Inlet Manifold 3 31 Inlet Manifold Inspection 3 32 Fuel Pump Fuel Filter oe d Eee eroe Batten cori e tet TR aie 3 33 Fuel Pump Removal 3 33 F el Pump InstallatiOr tenente eu eee ue en e aee tera ex e 3 33 Fuel Pump 3 33 Fuel Filter RemovalVlnstallation 3 34 Fuel Eilter InsSpecti n cte e Ee a ttr ea ie PERO RE E C a e be
2. amp EE 9 9 Charging System eere treat nic or Rte ea Foe Rack net sped Rue 9 10 Flywheel and Stator Ferme rer qon teet ere the deed 9 10 Flywheel and Stator Coil 0 1111 9 12 Charging System Operational Inspection 9 14 ele RE D 9 15 Unregulated Stator Outpt ER 9 15 PREQUIAUOR ne EE E 9 15 Regulator Installation i d t tetra bo neen 9 16 Reg lat r ResiStan epe eene Eegen 9 16 ignition Systemi E 9 17 e tg ele TR NEE 9 18 Ignition Coil Installation EE 9 18 ignition Coil IMSPSCUO Meenas ET 9 19 Spark Plug REMOVAl E 9 19 lee BE AUN EE 9 19 Spark Plug Cleaning and 9 19 Spark Plug Gap INSPECTION enm ener nennen neis 9 19 9 2 ELECTRICAL SYSTEM Exploded View KH020358W5 C ELECTRICAL SYSTEM 9 3 Exploded View N m 1 Flywheel Bolt 56 2 gnition Coil Bolts 5 9 3 Spark Plugs 22 4 Stator Coil Screws 3 4 6 FR and FS Models 7 FS Models 8 FS and FX Models G Apply dielectric grease 9 4 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Charging System Regulated Output Voltage Stator Coil Resistance Unregulated Stator Output Regulator Resistance Ignition System Ignition Co
3. 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 PERIODIC MAINTENANCE 2 3 Torque and Locking Agent The following tables list the tightening torque for the major fasteners and the parts requiring use of a non permanent locking agent or liquid gasket Letters used in the Remarks column mean EO Apply oil to the threads L Apply a non permanent locking agent to the threads Lh Left hand threads S Tighten the fasteners following the specified sequence Torque Fastener mem kgf m ftlb Remarks Fuel System Carburetor and Inlet Pipe Mounting Nuts 5 9 0 60 52 Control Panel Mounting Bolt 5 9 0 60 52 Governor Arm Clamp Nut 7 8 0 80 69 in Ib Governor Arm Joint Bolt 5 9 0 60 52 Lh Governor Shaft Plate Screws 2 0 0 20 18 in lb Inlet Manifold Bolts 5 9 0 60 52 in lb S FX Models Air Cleaner Bracket Mounting Bolts 5 9 0 60 52 in lb Air Cleaner Holder Bracket Bolts 5 9 0 60 52 Carburetor and Inlet Pipe Mounting Bolts 5 9 0 60 52 Choke Valve Screws 0 93 0 095 8 2 in lb Cover Plate Screw 24 0 24 21 in Ib Drain Screw 2 0 0 20 18 in Ib Float Chamber Mounting Screws 3 9 0 40 35 in Ib Throttle Valve Screws 0 93 0 095 8 2 FR and FS Models Control Panel and Inlet Pipe Mounting Bolt 5 9 0 60 52 in lb Main Je
4. A FR651V FR691V FR730V FS651V FS691V FS730V Ed Kawasaki FX651V FX691V FX730V 4 Stroke Air Cooled V Twin Gasoline Engine Service Manual This quick reference guide will assist you in locating a desired topic or pro cedure Bend the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the spe cific topic required Quick Reference Guide General Information Periodic Maintenance Fuel System Cooling System Engine Top End Lubrication System Camshaft Crankshaft Starter System Electrical System Troubleshooting FR651V FR691V FR730V FS651V FS691V FS730V FX651V FX691V FX730V Kawasaki 4 Stroke Air Cooled V Twin Gasoline Engine Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Division Consumer Products amp Machinery Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notic
5. Valve Guide Inside Diameter Valve Spring Inspection Cylinder Piston Removal Piston Installation Piston Cylinder Seizure Piston Cleaning Piston Ring and Ring Groove WAM see n e pes rd Piston Ring End Gap Piston Pin Piston Pin Hole Piston Diameter Cylinder Inside Diameter Cylinder Boring and Honing and Connecting Rod Wear ores 5 2 5 4 5 6 5 7 5 7 5 8 5 8 5 9 5 10 5 10 5 10 5 12 5 13 5 13 5 14 5 14 5 14 5 14 5 14 5 14 5 14 5 14 5 15 5 15 5 16 5 16 5 17 5 19 5 19 5 20 5 21 5 21 5 22 5 22 5 22 5 2 ENGINE TOP END Exploded View i dnt ENGINE TOP END 5 3 Exploded View Fastener Remarks 1 Connecting Rod Big End Cap Bolts 87 in lb 2 Head Bolts L 50 mm 34 S 3 Oylinder Head Bolts L 60 mm 34 S 4 Rocker Arm Bracket Bolts 11 L 5 Rocker Cover Bolts 5 9 0 60 52 1 S 6 Spark Plugs 22 2 2 16 7 Valve Clearance Adjusting Locknuts 11 1 1 97 in lb EO Apply engine oil L Apply a non parmanent locking agent MO Apply molybdenum disulfide oil R Replacement Parts S Tighten the fasteners following the specified sequence 5 4 ENGINE TOP END Specifications Item Service Lim
6. 1 8 L 1 9 US qt When the oil filter is removed 2 1 L 2 2 US qt e Check the O ring A on the oil filler cap for damage Re place the oil filler cap assembly if O ring is damaged xWhen checking the oil level do not turn oil filler cap threads NOTE OSome increase in oil consumption may be expected when a multi grade engine oil 10W 30 10W 40 5W 20 is used Check the oil level more frequently than recom mended interval Oil Filter Replacement e Drain the engine oil see Engine Oil Change e Using a suitable tool A remove the oil filter B OWhen unscrewing the oil filter place a suitable container beneath the oil drip tray to receive oil from the oil filter and oil passages in the engine e Replace the oil filter A with a new one e Apply light film of engine oil to the seal B e Install the oil filter OTurn the filter until the seal contacts mounting surface C of the engine Then turn the filter BY HAND S 3 4 turn e Run the engine at slow idle speed 3 minutes OWhile running the engine check for oil leaks around it e Stop the engine and check the oil level see Engine Oil Level Inspection lt Ambient Temperature gt 200_ 100 ot 1002 200 3002 407 KF05004BS1 PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures Electrical System Spark Plug Cleaning and Inspection e Carefully pull the plug cap from the spark plug an
7. Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a WARNING CAU TION or NOTE Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents jap SEM eiii WEE recedet ree o eodein re rer na e ug ee ugs nie day eeu e e General Specifications 1 2 GENERAL INFORMATION Before Servicing Before starting to service the engine carefully read the applicable section to eliminate unnecessary work Photographs diagrams notes cautions warnings and detailed descriptions have been in cluded wherever necessary Nevertheless even a detailed account has limitations a certain amount of basic knowledge is required for successful 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 sa
8. 3 Cover Oil Passage Plugs 3 9 0 40 35 in Ib L 4 Crankcase Oil Passage Plugs 3 9 0 40 35 in lb L 5 Breather Chamber Cover Bolts 5 9 0 60 52 mb 6 Breather Valve Mounting Screw 2 0 0 20 18 in Ib EO Apply engine oil G Apply grease L Apply a non parmanent locking agent Mi Apply mineral oil MO Apply molybdenum disulfide oil R Replacement Parts S Tighten the fasteners following the specified sequence 7 4 CAMSHAFT CRANKSHAFT Specifications Item Service Limit Camshaft Tappet Cam Lobe Height Inlet Exhaust Camshaft Journal Diameter PTO Side Flywheel Side Camshaft Bearing Inside Diameter Crankcase Crankcase Cover Crankshaft Connecting Rod Connecting Rod Bend Connecting Rod Twist Connecting Rod Big End Width Crankpin Width Connecting Rod Big End Inside Diameter Crankpin Outside Diameter Crankshaft Runout Crankshaft Journal Diameter PTO Side Flywheel Side Crankcase Crankshaft Bearing Inside Diameter Crankcase Crankshaft Journal Bearing Inside Diameter Crankcase Cover 29 36 mm 1 156 in 29 36 mm 1 156 in 15 99 mm 0 630 in 15 99 mm 0 630 in 16 119 mm 0 6346 in 16 119 mm 0 6346 in TIR 0 15 100 mm 0 006 3 94 in TIR 0 15 100 mm 0 006 3 94 in 22 05 mm 0 868 in 44 7 mm 1 76 in 40 04 mm 1 58 in 39 94 mm 1 57 in TIR 0 05 mm 0 002 in 39 90 mm 1 571 in 39 88 mm 1 570 in 40 035
9. Do not reuse the snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Apply engine oil to the piston skirt and the cylinder bore e Using the piston ring compressor grip A and the belt B lightly tap the top of the piston with a plastic mallet C to insert the piston and connecting rod into the cylinder Special Tools Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 67 79 57001 1097 e Insert the piston and connecting rod so that the arrow mark A on the top of the piston is facing the flywheel side KE08123BS1 C Cylinder Piston ENGINE TOP END 5 19 CAUTION The connecting rod and the connecting rod big end cap are machined at the factory in the assembled state so they must be replaced together as a set e Apply molybdenum disulfide oil solution oil to the inner surface A of the connecting rod big end B and caps C OThe molybdenum disulfide oil solution is a mixture of en gine oil and molybdenum disulfide grease with a weight ratio 10 1 e Install the connecting rod big end caps on their original position on each connecting rod big ends e Apply a thin layer of engine oil to the thread D and seat ing surface E of the cap bolts e Tighten Torque Connecting Rod Big End Cap Bolts 9 8 N m 1 0 kgf m 87 in lb e Install the removed parts see appropriate chapters Piston Cylinder Se
10. Push Rod see Push Rod Removal Rocker Arm Bracket Bolts A Rocker Arm Bracket B e Remove the cylinder head assembly see Cylinder Head Assembly Removal 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 suitable tool and remove the collets e Remove the valve retainer spring C and valve e Remove the stem seals A NOTE Olt is not necessary to remove the stem seal unless it is being replaced OValve guide B is not replaceable do no remove it e Apply engine oil to the valve stem to avoid damaging the stem seal e Check to see that the valve moves smoothly up and down in the guide e Check to see that the valve seats properly in the valve seat A If it does not repair the valve seat see Valve Seat Repair in the Periodic Maintenance chapter e Valve installation is the reverse of removal e Install the cylinder head assembly see Cylinder Head As sembly Installation e Set the each piston at T D C of the compression stroke see Cylinder Head Assembly Installation 5 12 ENGINE END Cylinder Head e Install the rocker arm brackets A so that bracket hollows B fit to the cylinder head projections C e Apply a non permanent locking agent to the rocker arm bracket bolts and tighten them Torque Rocker Arm Bracket Bolts 14 7 N m 1 5 kgf m 11 ft Ib e Install the push rods
11. The dif ference between the highest and lowest dial gauge read ings TIR is the amount of runout x If the measurement exceeds the service limit replace the crankshaft with a new one KG08042BS1 C Crankshaft Runout Service Limit TIR 0 05 mm 0 002 in 7 20 CAMSHAFT CRANKSHAFT Crankshaft Connecting Rod Crankshaft Main Journal Wear Measure both main journals at several points around the journal circumference xIf the journal diameter is less than the service limit re place the crankshaft with a new one Crankshaft Journal Diameter Service Limit PTO Side A 39 90 mm 1 571 in Flywheel Side B 39 88 mm 1 570 in STARTER SYSTEM 8 1 Starter System Table of Contents Exploded VIew 4a pde ote epiac Mutant i kate oto a cte e ER PORE Mg Le PO Mt 8 2 eene de EE 8 4 GE 8 5 Starter Motor Removal 8 5 Starter Motor euis pn detecte tette tton na quce eus euet eee ee siue 8 5 Starter Solenoid and Circuit 8 5 Starter Motor EE 8 7 Starter Motor Disassembly pp 8 7 Starter Motor Assembly E 8 9 Starter Motor Brush Inspection ener nnne nnns 8 12 Brush Spring Inspection rre dn erret reet e Lec reae d Tre hens 8 12 Armature 8 13 Yoke Assembly InSpectlOD BEE 8 15 Pinion Gl tchiInspectlOn noire oit eo et nr e RE ERE T POM DS oun dd 8 15 8
12. and cover plate x If there is any damage or uneven wear replace them with new ones OCheck the clearance A between the inner and outer rotor with a feeler gauge Measure the clearance between the high point of the inner rotor and the high point of the outer rotor x If the measurement exceed the service limit replace the rotors as a set with new ones Inner and Outer Rotor Clearance Service Limit 0 2 mm 0 008 in 6 10 LUBRICATION SYSTEM Oil Pump Relief Valve e Measure the outside diameter A of the outer rotor with a micrometer at several points x If the rotor diameter is less than the service limit replace both the inner and outer rotor with new ones Outer Rotor Outside Diameter Service Limit 52 31 mm 2 059 in Measure the thickness B of the outer rotor with a mi crometer at several points x If the rotor thickness is less than the service limit replace both the inner and outer rotor with new ones Outer Rotor Thickness Service Limit 14 91 mm 0 5870 in e Measure the inside diameter A of the pump housing with a inside micrometer at several points xIf the inside diameter is more than the service limit re place the crankcase cover with a new one Pump Housing Inside Diameter Service Limit 52 721 mm 2 0756 in e Measure the depth B of the pump housing with a depth micrometer at several points any of measurement is more than the service limit re place the
13. tools until it is flush with flange surface E or maximum 1 mm 0 04 in F lower than the flange surface Do not damage the seal lip Flywheel Side G e Install the removed parts see appropriate chapters Crankcase Inspection e Measure the inside diameter A of the crankshaft in sert on the crankcase at several points Replace the crankcase if the inside diameter is more than the service limit Crankshaft Bearing Inside Diameter Service Limit 40 035 mm 1 576 in Crankcase and Crankcase Cover Cleaning e Remove Oil Pump and Relief Valve see Oil Pump Relief Valve Removal in the Lubrication System chapter Camshaft and Tappets see Camshaft Tappet Removal Crankshaft see Crankshaft Removal Breather Valve and Cover see Breather Valve Removal e Clean up the crankcase and cover with a high flash point solvent and blow out any foreign particles that may be in the pockets inside of the crankcase with compressed air A WARNING Clean the crankcase and cover in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents 7 10 CAMSHAFT CRANKSHAFT Breather The function of the breather is to create a negative pressure 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 emissi
14. 3 Blades KH07058BS1 C A B C A oo oo B oo G oo 0 D over than over than over than _ 1 MQ 1 MQ 1 MO OResistance value may vary with individual meters xIf the resistance is not as specified replace the regulator with a new one ELECTRICAL SYSTEM 9 17 Ignition System This engine ignition is controlled by a solid state ignition assembly and requires no periodic main tenance except for the spark plugs The system consists of the following Inductive Ignition Assemblies Permanent Magnet Flywheel Spark Plugs Stop Switch D1 SW KH080558W2 C Co Core Lamination C Collector F Flywheel D1 Diode E Emitter M Magnet L1 Primary Coil R1 Control Resistor N North Pole L2 Secondary Coil TS1 Trigger Sensor S South Pole Q1 Transistor SP Spark Plug B Base SW Stop Switch Ignition System Operation Theory Permanent magnets are mounted around the edge area of a flywheel As the flywheel magnetic pole rotates clockwise and passes the ignition module on a laminated core group voltage is produced at the primary winding L1 allowing a small bias current to flow from the control resister R1 to the transistor Q1 base and thereby exciting the transistor base Thus the transistor forms turns ON the primary circuit This circuit current flows from the plus side of the primary winding to ground through the transistor Collector C to Emitter E When
15. 57001 221 Compression Gauge Adapter M14 x 1 25 B 57001 1159 e Ground the spark plugs to the engine A WARNING To avoid fire do not ground the spark plugs in prox imity to the plug holes Keep the plugs as far away as possible from the plug holes e Open the throttle fully Run the engine by turning the en gine switch key several times until the compression gauge stops rising Read the highest compression value Cylinder Compression MIN 440 kPa 64 psi Engine Oil Temperature 50 60 C 122 140 F Cranking Speed 450 rpm 5 Seconds e Repeat the measurement on the other cylinder x If the compression is higher than the specified value the piston rings cylinder and valves are probably in good con dition x If the compression is 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 accumula tion 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 x If the cylinder compression is lower than the MIN check the following 1 Gas leakage around the cylinder head replace the damaged gasket with a new one and check the cylinder head warp Condition of th
16. A measure the valve clearance between the rocker arm B and the valve stem end x If the valve clearance is incorrect adjust it Valve Clearance when cold Inlet Exhaust 0 10 0 15 mm 0 004 0 006 in Valve Clearance Adjustment e Since valve repairs change the valve clearance adjust the valve clearance to the specified e Turn the crankshaft in proper direction until the piston is at the TDC of the compression stroke as described above e Loosen the locknut A and adjusting bolt B e Insert a 0 05 mm 0 0020 in thickness gauge C be tween the rocker arm and valve stem end and turn the adjusting bolt until the thickness gauge begins to bind be tween the rocker arm and valve stem end Sweep the thickness gauge during this adjustment Valve Clearance when cold Inlet Exhaust 0 10 0 15 mm 0 004 0 006 in 2 12 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Holding the adjusting bolt with a spanner A tighten the adjusting locknut B to the specified torque Torque Valve Clearance Adjusting Locknuts 11 N m 1 1 kgf m 87 in Ib e Do not overtighten the valve clearance adjusting locknuts e After the valve clearance adjustment measure the valve clearance again Readjust the valve clearance if neces sary Valve Seat Inspection e Remove the valve see Valve Mechanism Removal Instal lation in the Engine Top End chapter e Inspect the valve seats for damage xIf the seat
17. END 5 5 Item Standard Valve Clearance Inlet Exhaust Valve Seating Surface Angle Inlet Exhaust Valve Seating Surface Width Inlet Exhaust Valves Guide Inside Diameter Inlet Exhaust Cylinder Inside Diameter Standard Cylinder 0 50 mm Oversize Cylinder 0 10 0 15 mm 0 004 0 006 in 45 1 2 1 8 mm 0 047 0 071 in 0 8 1 6 mm 0 031 0 063 in 6 000 6 012 mm 0 2362 0 2367 in 77 98 78 00 mm 3 070 3 071 in 78 48 78 50 mm 3 090 3 091 in 5 6 ENGINE END Special Tools Piston Ring Pliers 57001 115 7570115ST C Compression Gauge 20 kgf cm 57001 221 Piston Ring Compressor Grip 57001 1095 7570221ST C 7571095ST C Piston Ring Compressor Belt 67 79 57001 1097 7571097ST C Compression Gauge Adapter M14 x 1 25 57001 1159 875711595 Head ENGINE TOP END 5 7 Compression Measurement e Before measuring compression do the following OBe sure the battery is fully charged OThoroughly warm up the engine so that engine oil be tween the piston and cylinder wall will help sealing the compression as it does during normal running OStop the engine e Disconnect the spark plug caps of each cylinder and re move the spark plugs e Attach the compression gauge assembly firmly into one plug hole Special Tools Compression Gauge 20 kgf cm A
18. ERR 3 34 Air Cleaner itt PO EEG EE S RA RR REX EY DRE REMIT Dea Utenti e DE GERE RS 3 35 Element Rermovali t ett aa e dE AY Ee e ORA ARRA 3 35 Element Installapon 3 36 Element Cleaning and Inspection ss io codec tete ed nt esie toe acc Bede one Sce 3 37 Air Cleaner Body and Bracket Removal pp 3 37 Air Cleaner Body and Bracket Installation ppp 3 38 Air Cleaner Housing Cap and Body 3 38 3 2 FUEL SYSTEM Exploded View FX Models FUEL SYSTEM 3 3 Exploded View Fastener Tordue Remarks kgf m Air Cleaner Bracket Mounting Bolts 52 in lb Air Cleaner Holder Bracket Bolts 52 in lb Carburetor and Inlet Pipe Mounting Bolts 52 in lb Carburetor and Inlet Pipe Mounting Nuts 52 in lb Choke Valve Screws 8 2 in Ib Cover Plate Screw 21 in lb Drain Screw 18 in Ib Float Chamber Mounting Screws 35 in lb Inlet Manifold Bolts 59 060 52inlb S Throttle Valve Screws 0 93 0 095 8 2 in Ib R Replacement Parts S Tighten the fasteners following the specified sequence co Oo O1 AIIN gt ei 3 4 FUEL SYSTEM Exploded View FR651V FR691V FR730V FS651V FS691V FS730V Models FUEL SYSTEM 3 5 Exploded View Fastener rene Remarks kgf m Carburetor and Inlet Pipe Mounting Nuts 52 in lb Control Panel and Inlet Pipe Mounting Bolt 52 in Ib
19. I Repair or replace Faulty pinion clutch Faulty engine Starter does not stop in engine switch OFF Can stop starter by engine NO Faulty engine switch or replace switch OFF Faulty solenoid switch Replace YES Faulty pinion orring or replace Incorrect starter alignment Correct Faulty pinion return Repair or replace mechanism KI03022B F Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 2093 03 Printed in Japan
20. System Table of Contents leie e WEE 6 2 Engine Oil Flow C m 6 4 leet 6 5 ee Ne EE 6 6 Engine Oil Ang ERT ET 6 7 Engine Oil Level Inspection E 6 7 Engine MANGO es m 6 7 E 6 7 Oil Filter Installations coca corno tree ec rr e on Pressurized Lubrication Oyster coc E Oil Pressure Measurement eene Oil Pump Relief Valve 6 9 Oil Pump Relief Valve Removal 0000000 6 9 Oil Pump Relief Valve Installation pt 6 9 Oil Pump Relief Valve Inspechon me 6 9 OIL WEE 6 11 1 5 i icta be n de n d PE 6 11 Oil Screen lnstallati Nr mtt t esee cre t dete p Eta Ponce f Dl Le L a etd 6 11 Cleaning Inspection EE 6 11 6 2 LUBRICATION SYSTEM Exploded View KF020208N5 C LUBRICATION SYSTEM 6 3 Exploded View Fastener Remarks 1 Engine Oil Drain Plug 6 9 0 70 61 in Ib 2 Oil Filler Mounting Bolt FX Models 5 9 0 60 52 in lb Oil Filler Mounting Bolt FR and FS Models 8 8 0 90 78 in lb 3 Pump Cover Plate Bolts 5 9 0 60 52 in Ib EO Apply engine oil G Apply grease R Replacement Parts 6 4 LUBRICATION SYSTEM Engine Oil Flow Chart N 5 5 4 e A N 5 EJ 22 SS
21. band A 19 E t d 41 1 5 58 Engine Shroud Installation FX Models e Install the engine shroud A e Tighten Torque Engine Shroud Bolts B 5 9 N m 0 60 kgf m 52 in Ib 4 6 COOLING SYSTEM Engine Shroud FR and FS Models e Install the engine shrouds NOTE OBend the engine shroud regulator side A only within the shown range 70 B e Attach the stator coil lead ignition coil lead and solenoid valve connector lead to the engine shroud with the band e Tighten Torque Engine Shroud Bolts 8 8 N m 0 90 kgf m 78 in Ib e Install the removed parts see appropriate chapters KC10019BS1 C ENGINE TOP END 5 1 Engine Top End Exploded View Specifications Special Tools Cylinder Compression Measurement Table of Contents Cylinder Head Assembly Removal pp Cylinder Head Assembly Installation pp Push Rod Removal Push Rod Installation Push Rod Inspection Valve Mechanism Remowval Installation pp Cylinder Head Cleaning Cylinder Head Inspection Rocker Arm Inspection Valve Clearance Inspection Valve Clearance TEE Valve Seat Inspection Valve Seat Repair Valve Head Thickness Valve Stem Runout Valve Stem Diameter
22. clip end e Remove the carburetor FX Models D FR and FS Models E Carburetor FUEL SYSTEM 3 23 Carburetor Installation e Clean the mating surface of the carburetor and inlet man ifold e Replace the gaskets A with new ones e Install the insulator B carburetor C and gaskets se quence as shown in the figure e Apply dielectric grease to the solenoid valve connector Connect the solenoid valve connector OThe tongue D of the gaskets face the PTO side FX Mod els only FX Models E FR and FS Models F KC05181BS2 C KC05189BS2 C 3 24 FUEL SYSTEM Carburetor e Install the throttle link rod A and spring B to the throttle shaft lever clip C NOTE OTake care not to bend the throttle link rod during instal lation e Make sure the link spring around the throttle link rod is in place and that it pulls the governor arm and carburetor throttle shaft lever toward each other FX Models D FR and FS Models E e Install the fuel tube A fully so that the clamp knob B faces the downward e Install the removed parts see appropriate chapters e After installation adjust the idle speed see Low High Idle Speed Adjustment in the Periodic Maintenance chapter FX Models C FR and FS Models D Carburetor FUEL SYSTEM 3 25 Carburetor Disassembly Assembly FX Models e Refer to the illustration shown for disassembly and as sembly e There are several passage
23. crankcase cover with a new one Pump Housing Depth Service Limit 15 16 mm 0 5968 in e Visually inspect the relief valve spring steel ball and valve seat in the crankcase cover If any rough spot is found during above inspection wash the valve clean with a high flash point solvent and blow out any foreign particles on the valve with compressed air A WARNING Clean the parts in a well ventilated area and take care that there is no spark or flame anywhere near the working areas Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents x If cleaning does not solve the problem replace the relief valve parts with new ones x lf necessary put the ball in position and lightly tap the ball with a suitable tool to form a perfect seat Measure the free length A of the spring with a vernier caliper x If the free length of the spring is less than the service limit replace the spring with a new one Relief Valve Spring Free Length Service Limit 20 4 mm 0 803 in LUBRICATION SYSTEM 6 11 Cil Screen Oil Screen Removal e Remove the oil pump cover plate see Oil Pump Relief Valve Removal e Remove the oil screen A Oil Screen Installation e Clean the oil screen thoroughly whenever it is removed for any reason see Cleaning and Inspection e Insert the oil screen A in position e Install the oil pump cover plate see Oil Pump Relief Valve Instal
24. figure e Install the armature assembly A to the pinion gear cover B Install the yoke so that the slit A fit the projection B of the pinion gear fork e Install the brush holder A e Install the brushes B to the brush holder e Install the springs A STARTER SYSTEM 8 11 Electric Starter System e Install the insulator Install the end cover so that the slit A fit the groove B of the grommet e Tighten the through bolts e Engage the hook on the starter solenoid with the hook A on the pinion gear fork B e Tighten the solenoid mounting nut FR and FS Models e Using the suitable tool hold the brushes e Install the armature assembly to the brush plate assem bly e Install the yoke so that the slit A fit the groove B of the brush plate assembly 8 12 STARTER SYSTEM Electric Starter System e Apply grease to the armature shaft e Install the end cover so that the slit A fit the projection B of the yoke e Tighten Torque Starter Motor Through Bolts 3 95 0 40 kgf m 35 in Ib e Install Collar A Rubber Damper B Pinion Gear C Spring D Washer E e Make sure that grease does not attach to the contact por tion between the collar and the rubber damper e Tighten the nut F Starter Motor Brush Inspection e Measure the overall length A of each brush x If the brushes are shorter than the service limit replace
25. left pole plate of magnet E between center of ignition coil and right pole plate of magnet Ignition Coil Air Gap D and E Standard 0 2 0 4 mm 0 008 0 016 in Torque Ignition Coil Bolts 5 9 N m 0 60 kgf m 52 in Ib NOTE OUse the above procedure to insure proper coil air gap e Fit the ignition coil leads A to the each engine shroud groove B e Install the spark plug cap C ELECTRICAL SYSTEM 9 19 Ignition System Ignition Coil Inspection e Remove the ignition coil see Ignition Coil Removal e Measure the winding resistance as follows OSet the hand tester to the R x 1 kO range Special Tool Hand Tester 57001 1394 OMeasure the ignition coil winding resistance as shown in the table Ignition Coil Winding Resistance 10 20 C 10 20 18 28 CAUTION room temperature for this test A tester other than the Kawasaki Hand Tester should show different readings If a megger or a meter with a large capacity battery is used the ignition coil will be damaged Use only Tester 57001 1394 with new battery at xIf the tester does not read as specified replace the coil with a new one Spark Plug Removal e Carefully pull the plug caps from the spark plugs e Remove the spark plugs using a suitable plug wrench Spark Plug Installation e Insert the spark plug vertically into the plug hole with the plug installed in the plug wre
26. mm 1 576 in 40 005 mm 1 575 in CAMSHAFT CRANKSHAFT 7 5 Special Tool Bearing Driver Set Liquid Gasket TB1217H 57001 1129 92104 7001 7571129ST C 879270015 7 6 CAMSHAFT CRANKSHAFT Crankcase Crankcase Cover Removal e Set the engine on a clean surface while parts are being removed e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Oil Filter see Oil Filter Replacement in the Periodic Maintenance chapter Inlet Manifold see Inlet Manifold Removal in the Fuel System chapter Ignition Coils see Ignition Coil Removal in the Electrical System chapter Flywheel and Stator Coil see Flywheel and Stator Coil Removal in the Electrical System chapter Starter Motor see Starter Motor Removal in the Starter System chapter Governor Arm see Governor Arm Removal in the Fuel System chapter e Unscrew the mounting bolts in the order shown 1 to 10 and remove the crankcase cover from the crankcase OThere are two dowel pins on the crankcase mating surface Using a wooden or plastic mallet gently tap crankcase to loosen the crankcase cover Crankcase Cover Disassembly e Remove Crankcase Cover see Crankcase Cover Removal Governor Shaft see Governor Shaft Removal in the Fuel System chapter e Pry the governor shaft oil seal A with the suitable tool and remove it e Pry the crankshaft oil seal A with the suitable tool and rem
27. on the crankcase cover at several points Re place the crankcase cover if the inside diameter is more than the service limit Crankshaft Journal Bearing Inside Diameter Service Limit 40 005 mm 1 575 in Crankcase Disassembly e Remove Crankcase Cover see Crankcase Cover Removal Camshaft and Tappets see Camshaft Tappet Removal Crankshaft see Crankshaft Removal Pry the crankshaft oil seal A with the suitable tool and remove it Crankcase Assembly e Remove the old gasket from the mating surfaces of the crankcase and cover e Using compressed air blow out the oil passage in the crankcase e With a high flash point solvent clean off the mating sur faces of the crankcase and the cover and wipe them dry A WARNING Clean the crankcase and cover in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean parts A fire or explosion could result KG04088BS1 C CAMSHAFT CRANKSHAFT 7 9 Crankcase e Be sure to replace any oil seal with a new one if removed OApply mineral oil to the crankshaft oil seal outside Olnstall the oil seal so that the marks A face out OThoroughly pack high temperature grease to 60 volume into the space B between the dust lip C and seal lip D Press in the new oil seal using a press or suitable
28. plugs ball plugs in the car buretor body Do not remove e Before disassembly mark the out side of choke and throt tle valves for assembling them 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 into the carburetor body e Assemble carburetor parts with recommended tightening torque see Exploded View 1 Pilot Screw Plugs 19 Main Jet R 2 Pilot Screws 20 O rings 3 Screw 21 Gasket 4 Cover Plate 22 O ring 5 Pilot Jet Holder 23 Spacer 6 O ring 24 Pin 7T Screws 25 Float Valve 8 Choke Valve 26 Float 9 Choke Shaft 27 O ring 10 Collar 28 Gasket 11 Seal 29 Float Chamber 12 Collar 30 Screws 13 Screws 31 Solenoid Valve 14 Throttle Valves 32 Gasket 15 Throttle Shaft 33 Drain Screw 16 Throttle Shaft Holder 34 Spring 17 Seal 35 Screw 18 Main Jet L KC05180BS3 C 3 26 FUEL SYSTEM Carburetor FR651V FR691V FS651V FS691V Models e Refer to the illustration shown for disassembly and as sembly e There are several passage plugs ball plugs in the car buretor body Do not remove e Before disassembly mark the out side of choke and throt tle valves for assembling them 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 into the carburetor body e Assemble carburetor parts with recommended tightening torque s
29. replace the valve with a new one Valve Stem Diameter Service Limit Inlet 5 95 mm 0 234 in Exhaust 5 93 mm 0 233 in KE05008BS1 60 Valves ENGINE TOP END 5 15 Valve Guide Inside Diameter e Use a small bore gauge or a micrometer to measure the inside diameter A of the valve guide B at three positions down the guide length x If the measurement is more than the service limit replace the cylinder head with a new one Valve Guide Inside Diameter Service Limit Inlet Exhaust 6 08 mm 0 239 in Valve Spring Inspection e Inspect the valve spring for pitting cracks rusting and burns Replace the spring with a new one if necessary e Measure the free length A of the spring x If the measurement is less than the service limit replace the spring with a new one Valve Spring Free Length Service Limit Inlet Exhaust 31 0 mm 1 22 in GF08080381 C 5 16 ENGINE END Cylinder Piston Piston Removal e Remove Cylinder Head Assembly see Cylinder Head Assembly Removal Crankcase Cover see Crankcase Cover Removal in the Camshaft Crankshaft chapter Camshaft see Camshaft Tappet Removal in the Camshaft Crankshaft chapter e Turn the crankshaft to expose the connecting rod cap bolts A e Remove the bolts and take off the connecting rod caps B NOTE ONote the positions of the connecting rod caps for rein stalling the caps e Scrape the carbon depsits from t
30. see Push Rod Installation e Position the rocker arm A so that the hollow side B faces push rod e Apply engine oil to the collars A e For 1 cylinder insert the collars in to the rocker arm hole so that the flatten side B faces PTO side e Insert the washers C onto the valve clearance adjusting bolts D and install them from the flywheel side hole of the rocker arms OAlign the flatten surface of the collars with the flatten sur face E of the valve clearance adjusting bolts e For 2 cylinder insert the collars in to the rocker arm hole so that the flatten side faces flywheel side e Insert the washers onto the valve clearance adjusting bolts and install them from the PTO side hole of the rocker arms OAlign the flatten surface of the collars with the flatten sur face of the valve clearance adjusting bolts Tighten the valve clearance adjusting locknuts temporar ily e Position the push rod end on to the rocker arm hollow e Adjust the valve clearance see Valve Clearance Adjust ment in the Periodic Maintenance chapter Cylinder Head Cleaning e Refer to the Cylinder Head Cleaning in the Periodic Main tenance chapter KE04044BS1 C Cylinder Head ENGINE TOP END 5 13 Cylinder Head Inspection e Lay a straightedge A across the mating surface of the head at several different points and measure warp by inserting a thickness gauge B between the straightedge and head
31. the base current is flowing the trigger sensor TS1 detects optimum time peak current to shut off the transistor base current With the transistor rapidly shutting off the current at the primary coil counter electromotive force is generated and voltage in hundreds volts is induced through the primary winding L1 thereby producing extremely high voltage at the secondary winding L2 When this secondary voltage steps up to k volts ionization meaning ignition occurs across the electrodes at the spark plug SP The trigger sensor located internally in the ignition system is set to give constant ignition timing according to engine speed and temperature The diode D1 located at the ignition shut off circuit prevents misconnection of battery voltage protecting the internal components of the ignition system When the stop switch SW is set at the closed position primary voltage is routed to ground not allowing igniting operation 9 18 ELECTRICAL SYSTEM Ignition System Ignition Coil Removal e Remove Fan Housing see Flywheel and Stator Coil Removal Spark Plug Cap A Bolts B Stop Switch Lead Connector C Ignition Coil D Ignition Coil Installation e Install the ignition coil on the crankcase so that the stop Switch lead connector A face the upward and tighten bolt B first then tighten bolt C While tightening bolts adjust the air gaps to specified gap value as shown D between left leg of ignition coil and
32. use scrapers that are made of a mate rial that will not cause damage e Clean the head in a bath of high flash point solvent and dry it with compressed air A WARNING Clean the cylinder head in a well ventilated area and take care that there are no sparks or flame any where near the working area this includes any ap pliance with a pilot light Do not use gasoline or a low flash point solvent to clean the cylinder head A fire or explosion could result Valve Clearance Inspection NOTE OValve clearance must be checked when the engine is cold at room temperature e Remove the rocker covers see Cylinder Head Assembly Removal in the Engine Top End chapter e Place the piston at the top dead center TDC of the com pression stroke by turning the crankshaft clockwise facing the flywheel 78070 P PERIODIC MAINTENANCE 2 11 Periodic Maintenance Procedures No 1 Cylinder OThe left projection A on the flywheel is faced with the right leg B on the 1 ignition coil C as shown in the figure OCheck the inlet and exhaust valves are closed completely if not turn the flywheel one turn 360 clockwise and face the left projection with the right leg again No 2 Cylinder OThe left projection A on the flywheel is faced with the right leg B on the 2 ignition coil C as shown in the figure Follow No 1 cylinder alignment e Then check the valve clearance OUsing a thickness gauge
33. 02 in 22 mm 0 87 in 20 mm 0 79 in 124 L 110 114 56 60 1 1 4 1 2 2 1 2 Float parallel to carburetor body Idle Speed 1 Low Idle Speed Carburetor idle rpm Low Idle Speed Governor idle rpm High Idle Speed 1 450 r min rpm 1 550 r min rpm 3 600 r min rpm Air Cleaner Type FR Models FS and FX Models Pre cleaner FR Models FS Models FX Models Second stage cleaner FS Models FX Models Single stage filtration system Dual stage filtration system Paper element Foam element Paper element Paper element Foam element FUEL SYSTEM 3 9 Specifications Fuel 2 Fuel Requirement Unleaded regular grade gasoline US Canada Using a minimum of 87 octane by antiknock index is recommended Antiknock Index RON MON 2 RON Research Octane Number MON Motor Octane Number Other Countries Using a minimum of 91 octane by RON is recommended 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 2 Other fuel requirements See Fuel and oil recommendations in Owner s Manual 3 10 FUEL SYSTEM Governor Link Mechanism Control Panel Assembly Removal FX Models e Remove Inlet Pipe Mounting Bolt A and Nut B Control Panel Mounting Bolt C Choke Spring D Control Panel Assembly E Governor Spring F FR and FS Mo
34. 2 99 in Piston Displacement Direction of Rotation 726 cm 44 3 cu in Counterclockwise facing the PTO shaft Compression Release Automatic compression release Low Idle Speed 1 550 r min rpm High Idle Speed 3 600 r min rpm Ignition System Transistorized flywheel magneto RFI Starting System FR and FS Models FX Models Per Canada and U S A requirements Electric starter Shift type electric starter Charging System FS and FX Models 12 V 15 amps with regulator FR Models 12 V 3 6 amp without regulator Spark Plug NGK BPRAES Carburetor FR and FS Models Float type fixed main jet internally vented single barrel FX Models Float type fixed main jet internally vented two barrel Fuel Pump Diaphragm type pulse pump Air Cleaner FR Models Single stage element dry type FS Models Dual stage element dry type FX Models Dual stage element heavy duty type Governor Flyweight all speed governor Lubrication System Pressure feed by positive displacement pump Oil Filter Cartridge type full flow filter Oil Capacity when engine is completely dry 2 0 L 2 1 US qt Cooling System Forced air cooling by fan Dimensions L x W x H FR Models 481 mm x 424 mm x 380 mm 18 9 in x 16 7 in x 15 0 in FS Models 481 mm x 424 mm x 380 mm 18 9 in x 16 7 in x 15 0 in FX Models 478 mm x 424 mm x 549 mm 18 8 in x 16 7 in x 21 6 in Dry Weight without muf
35. 2 STARTER SYSTEM Exploded View Exploded View STARTER SYSTEM 8 3 Remarks 1 Starter Motor Mounting Bolts 2 0 14 Starter Motor Through Bolts FR and FS Models 0 40 35 in lb 3 FR and FS Models G Apply grease R Replacement Parts 8 4 STARTER SYSTEM Specifications Standard Service Limit Electric Starter System Starter Motor Carbon Brush Lengh FX Models FR and FS Models FX Models FR and FS Models Commutator Diameter FX Models FR and FS Models Commutator Runout FX Models FR and FS Models Commutator Groove Depth 10 0 mm 0 39 in 0 6 mm 0 02 in 28 0 mm 1 10 in 6 0 mm 0 24 in 10 16 mm 0 4 in 0 2 mm 0 008 in 1 27 mm 0 05 in 27 0 mm 1 06 in 31 369 mm 1 235 in 0 4 mm 0 016 in 0 043 mm 0 0017 in Electric Starter System STARTER SYSTEM 8 5 Starter Motor Removal e Disconnect the wire e Remove the mounting bolts A and pull the starter motor B from the engine with the switch lead attached FX Models C FR and FS Models D Starter Motor Installation e Clean the starter motor and engine mounting flanges to ensure good electrical contact and tighten the mounting bolts Olnstall the hook A so that the stopper B of the hook contacts the crankcase Torque Starter Motor Mounting Bolts 19 6 2 00 kgf m 14 4 16 Starter Solenoid and Ci
36. 30 in lb The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners Threads Diameter Torque mm N m kgf m ft Ib 4 2 0 0 20 17 in Ib 5 3 4 0 35 30 in Ib 6 5 9 0 60 52 in Ib 8 15 1 5 11 10 20 2 0 15 Specifications PERIODIC MAINTENANCE 2 5 Standard Fuel System Idle Speed 1 Low Idle Speed Carburetor idle rpm 1 450 r min rpm Low Idle Speed Governor idle rpm High Idle Speed Air Cleaner Type FR Models FS and FX Models Pre cleaner FR Models FS Models FX Models Second stage cleaner FS Models FX Models 1 550 r min rpm 3 600 r min rpm Single stage filtration system Dual stage filtration system Paper element Foam element Paper element Paper element Foam element Engine Top End Valve Clearance Inlet Exhaust Valve Seating Surface Angle Inlet Exhaust Valve Seating Surface Width Inlet Exhaust Lubrication System Engine Oil Type Viscosity Capacity Level Electrical System Spark Plug Spark Plug Gap 0 10 0 15 mm 0 004 0 006 in 45 1 2 1 8 mm 0 047 0 071 in 0 8 1 6 mm 0 031 0 063 in SF SG SH SJ or SL class SAE 40 SAE 30 SAE 10W 30 SAE 10W 40 or SAE 5W 20 1 8
37. A out of the crankcase Tap gently with a wooden or plastic mallet if necessary to loosen the crankshaft Crankshaft Installation e Clean up the crankshaft and crankcase thoroughly espe cially at the bearing contact surfaces e Pack some amount of high temperature grease into the oil seals on the crankcase e Apply engine oil to the crankshaft journal e Apply molybdenum disulfide oil solution to the crankpin OThe molybdenum disulfide oil solution is a mixture of en gine oil and molybdenum disulfide grease with a weight ratio 10 1 e Carefully insert the crankshaft end into the main bearing in the crankcase Cleaning Inspection e After removing clean the crankshaft and the connecting rods with a high flash point solvent and dry them with compressed air e Inspect the teeth of the crankshaft gear for pitting fatigue cracks burrs and any evidence of improper tooth contact Replace the crankshaft with a new one if necessary e Inspect the crankshaft and connecting rods especially at the bearing surfaces for wear scratches any evidence of improper contact or other damages Replace them with new ones if necessary 7 18 CAMSHAFT CRANKSHAFT Crankshaft Connecting Rod Connecting Rod Bend Twist e Measure the connecting rod bend OSelect an arbor A of the same diameter as the connect ing rod big end and insert the arbor through the connect ing rod big end OSelect an arbor of the same diameter a
38. Diameter 0 50 mm 78 48 78 50 mm 3 090 3 091 in KE08122BS1 C Cylinder Piston ENGINE TOP END 5 23 Change to a honing stone for finishing the final bore di ameter should be as shown in the table Be sure the correct stone is used and the stone is not worn e Clean 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 e Align the center of the cylinder bore to the press center Set the press to operate from 200 250 rpm e Connect the drive shaft to the hone and set the stop on the drill press so the hone can only extend 20 25 mm 0 8 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 e 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 e Check the diameter of the cylinder bore regularly during honing using an inside micrometer LUBRICATION SYSTEM 6 1 Lubrication
39. ING 10 5 Engine Troubleshooting Guide Fuel consumption is excessive Is compression sufficient YES High fuel level in carburetor float chamber including overflow NO High idling RPM Choke partially closed Worn piston piston rings Stuck piston Worn cylinder bore Loose of cylinder head bolt Faulty valve seat contact Plunge up of valve Wrong valve timing Broken valve spring Stuck valve Cil consumption is excessive Is compression sufficient YES Plugged oil ring groove High oil level NO Worn valve stem and valve guide Oil leakage along governor shaft Oil leakage from oil seal Oil leakage from mounting surface Oil leakage from drain bolt Clogged breather valve Drain back hole breather chamber plugged Incorrect oil viscosity Worn piston rings Stuck piston rings Worn cylinder bore Broken piston ring Engine backfires Loose carburetor or inlet manifold loose cylinder head bolt or leaking head gasket Burned or sticking inlet valve Faulty ignition coil Carburetor not properly adjusted Engine knocks e Stale fuel Change Excessive carbon deposit in L Clean engine Excessive engine load Adjust Engine overheating See Engine power loss Faulty ignition coil Replace KI02147B F 10 6 TROUBLESHOOTING Starter Motor Troubleshooting Guide 1 Dis
40. Inlet Manifold Bolts 52 in lb Main Jet 20 in Ib Solenoid Valve 40 in lb Throttle Lever Mounting Screw FR651V FR691V FS651V FS691V Models Throttle Valve Screws 6 0 in Ib 8 FR730V and FS730V Models 9 FS Models L Apply a non permanent locking agent R S 6 0 Replacement Parts Tighten the fasteners following the specified sequence 3 6 FUEL SYSTEM Exploded View 0 2 FUEL SYSTEM 3 7 Exploded View Torque Fastener Remarks kgf m 1 Control Panel Mounting Bolt 5 9 0 60 52 in lb 2 Governor Arm Clamp Nut 7 8 0 80 69 in Ib 3 Governor Arm Joint Bolt 5 9 0 60 52 in lb Lh 4 Governor Shaft Plate Screws 2 0 0 20 18 in Ib 5 FR and FS Models EO Apply engine oil Lh Left hand threads R Replacement Parts 3 8 FUEL SYSTEM Specifications Item Standard Carburetor Specifications Make Type FR651V and FS651V FR691V and FS691V FR730V and FS730V FX651V FX691V FX730V Throttle Bore Diameter FR and FS Models FX Models Venturi Diameter FR and FS Models FX Models Main Jet MJ FR and FS Models FX Models Pilot Jet PJ FR and FS Models FX Models Pilot Air Screw Turns out PS Idle Mixture Screw Turns Out FR and FS Models FX Models Float Level Walbro LMF 23 Walbro LMF 26 Walbro LMF 22 Nikki 621266 A61 Nikki 621266 A51 Nikki 621266 A01 30 mm 1 18 in 26 mm 1
41. L 1 9 US qt When the oil filter is not removed 2 1 L 2 2 US qt When the oil filter is removed Operating range grid area ADD and FULL on dipstick BPR4ES 0 7 0 8 mm 0 028 0 031 in 1 Idle speeds may vary depending on each equipment Refer to the equipment specification 2 6 PERIODIC MAINTENANCE Special Tools Valve Seat Cutter 45 535 57001 1116 8 5711165 C Valve Seat Cutter 32 35 57001 1121 S T571121ST C Valve Seat Cutter Holder Bar 57001 1128 7571128ST C Valve Seat Cutter 45 530 57001 1187 7571187ST C Valve Seat Cutter 32 633 57001 1199 875711995 C Valve Seat Cutter Holder 6 57001 1360 ST571360ST PERIODIC MAINTENANCE 2 7 Periodic Maintenance Procedures Fuel System NOTE OHigh and low idle speeds may vary depending on the equipment on which the engine is used Refer to the equipment specification Low Idle Speed Adjustment e Disconnect all possible external loads from the engine e Start the engine and warm it up thoroughly WARNING Always keep your hands clear of the moving parts e Move the throttle lever at a dash to the idle position e Hold the throttle lever on the carburetor in closed position turn the governor arm clockwise all the way and adjust the low idle speed screw A until the engine idles at spec ified speed Low Idle Speed Carburetor i
42. add more oil above the operating range Ex cess oil will cause a smoking condition OUse the same type and make of oil that is already in the engine NOTE Olf the engine oil type and make are unknown use any brand ofthe specified oil to top up the level in preference to running the engine with the oil level low Then at your earliest convenience change the oil completely x If the oil level is FULL range F drain the excess oil by loosening the drain plug Engine Oil Change e Change the oil after first 8 hours of operation Thereafter change oil every 100 hours e Start and warm up the engine to drain the oil easily e Stop the engine e Place the engine on a level surface e Place a suitable container under the engine e Remove the oil drain plug A and drain the oil A WARNING Be careful of hot oil when draining It may be hot enough to burn you severely e Replace the O ring B with a new one e Apply grease to the O ring e Install the oil drain plug with the O ring and tighten it Torque Engine Oil Drain Plug 6 9 N m 0 70 kgf m 61 in Ib KMO8008BS1 C 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove the oil filler cap and pour in the specified type and the amount of oil Engine Oil Grade SF SG SH SJ or SL Class Viscosity SAE40 SAE30 SAE10W 30 SAE10W 40 or SAE5W 20 Capacity When the oil filter is not removed
43. amber Damaged cooling fan Is the ignition spark normal Wrong spark plug Faulty ignition coil Incorrect air gap Engine oil level too low or high Excessively contaminated engine oil Defective oil filter Faulty relief valve Faulty oil pump Clogging oil system Is lubricating condition normal Is unusual smoke emitted out of muffler Plugged air cleaner element Clean or replace Carbon deposit in exhaust hole Clean and muffler Carburetor not properly adjusted Adjust Engine oil level too high Adjust level Worn piston piston rings Replace Worn cylinder bore Bore or replace NO gt See Engine hard to start Is compression sufficient Engine runs erratically Problem in the engine Spark plug fouled pitted or Replace or adjust rotation gapped incorrectly Problem in the fuel system Entry of dust or water into fuel Clean lack of fuel hose or fuel filter Air or vapor lock in fuel line Clean Plugged air vent of fuel tank cap Clean Plugged air fuel passes in Clean carburetor Carburetor not properly adjusted Adjust Carburetor flange leaking at Retighten or replace gasket Worn carburetor body and Replace throttle shaft KI02146B F 10 4 TROUBLESHOOTING Engine Troubleshooting Guide Incorrect governor linkage Correct adjustment Faulty governor spring Replace Governor assy
44. at repair Therefore the cutter must not be used for other purposes 2 Do not drop or hit the valve seat cutter or the diamond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE ODo not use a wire brush to remove the metal particles from the cutter It will take off the diamond particles KM07019BS1 C 4 Setting the valve seat cutter holder A in position op erate the cutter B with one hand C Do not apply too much force to the diamond portion NOTE OPrior to grinding apply engine oil to the cutter and dur ing 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 32 Cutter angle A 37 5 Cutter diameter B KS8B Manufactured lot number KE05016BS1 C Operating Procedures e Clean the seat area carefully e Recondition the valve seats with the valve seat cutters 45 32 and lap the valves e Check the seats for good contact all the way around with 45 machinist s dye e Measure the seat width A If itis more than the standard width the seating surface should be refaced x If the valve seating pattern is not correct r
45. at the marks D face out Do not damage the seal lip OThe depth is 0 2 mm 0 0 08 in E e Install the governor shaft and plate see Governor Shaft Installation in the Fuel System chapter e Install the crankcase cover see Crankcase Cover Instal lation KGO4090BS1 C Crankcase Cover Installation e Align the inner rotor groove to the center of the crankcase cover see Oil Pump Relief Valve Installation in the Lu brication System chapter e Apply liquid gasket A to the mating surface of the crankcase cover Sealant Liquid Gasket TB1217H 92104 7001 NOTE OMake the application finish within 5 minutes when the liquid gasket to the mating surface of the crankcase cover is applied OMoreover fit the case and tighten the cover bolts just after finishing the application of the liquid gasket KG04086BS1 C 7 8 CAMSHAFT CRANKSHAFT Crankcase e Check to see that the dowel pins A O rings B and plas tic pipe C are in place on the crankcase e Install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence as shown in the figure Torque Crankcase Cover Bolts 27 4 N m 2 8 kgf m 20 ft lb ODo not turn one screw down completely before the others as it may cause the crankcase cover to warp e Install the removed parts see appropriate chapters Crankcase Cover Inspection e Measure the inside diameter A of the crankshaft journal bearing
46. cement 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 18 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure 19 Service Data Service Data terms are defined as follows Standards show dimensions or performances which brand new parts or systems have 1 4 GENERAL INFORMATION Before Servicing Service Limits indicate the usable limits If the measurement shows excessive wear or deteri orated performance replace the damaged parts GENERAL INFORMATION 1 5 Model Identification FX Models FR Models 1 6 GENERAL INFORMATION Model Identification FS Models Cylinder Number Designation No 1 Cylinder is the left hand cylinder viewed from the inlet pipe No 2 Oylinder is the right hand cylinder viewed from the inlet pipe General Specifications GENERAL INFORMATION 1 7 Item FR651V FR691V FR730V FS651V FS691V FS730V FX651V FX691V FX730V Type of Engine Forced air cooled vertical shaft OHV 4 stroke gasoline engine Cylinder Layout 90 V Twin Bore x Stroke 78 mm x 76 mm 3 07 in x
47. connect spark plug caps from the spark plugs 2 Turn engine switch to START position and check condition A WARNING ment during test Engine may be cranked in this test Do not touch any rotating parts of engine and equip CAUTION If starter does not stop by engine switch OFF disconnect negative cable from battery as soon as possible Starter does not rotate NO Faulty battery Charge or replace Faulty leads or connection replace Melted fuse Replace Faulty engine switch Repair or replace YES Faulty solenoid switch Replace Is click sound from solenoid switch Weak battery or replace Faulty leads or connection I Repair or replace Solenoid to motor Faulty solenoid switch Replace Main terminal in solenoid Faulty starter motor Repair or replace Starter rotates but slow Is EE normal and well e e Weak battery Weak battery Charge or replace EE Faulty leads or connection Repair or replace Solenoid to motor Faulty solenoid switch Replace Main terminal in solenoid Faulty starter motor Repair or replace Faulty engine Repair or replace Starter rotates but engine can not crank Does pinion mesh with ring NO Worn pinion or ring gear Replace gear Incorrect starter alignment Correct YES I Replace
48. crews particularly for the removal of screws held by a locking agent in order to avoid damaging the heads 6 Edges Watch for sharp edges especially during major engine disassembly and assembly Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent com monly available in North America is Standard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent 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 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 Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary Replace any ball or needle bearings that were removed
49. ct electrical sys tem operation OMeasure the coil and the winding resistance when the parts are cold at room temperature OElectrical connectors Connectors A Connectors B GP07000281 60 GP07000381 C 9 10 ELECTRICAL SYSTEM Charging System Flywheel and Stator Coil Removal FX Models e Remove Air Cleaner see Air Cleaner Body and Bracket Removal in the Fuel System chapter Fuel Pump see Fuel Pump Removal in the Fuel System chapter Stator Coil Lead Connector see Regulator Removal Bolts A and Guard B FS Models e Remove Element Assembly see Element Removal in the Fuel System chapter Fuel Pump see Fuel Pump Removal in the Fuel System chapter Stator Coil Lead Connector see Regulator Removal Screw Rivets A and Guard B e Remove Bolts A and Screen B Spacer e Remove Bolts A Fan Housing B FX Models C FS Models D ELECTRICAL SYSTEM 9 11 Charging System FR Models e Remove Paper Element see Element Removal in the Fuel Sys tem chapter Fuel Pump see Fuel Pump Removal in the Fuel System chapter Bolts A Fan Housing B Cooling Fan Screen Bolts Cooling Fan Screen e Remove Ignition Coils see Ignition Coil Removal Bolts A Plate B Cooling Fan C e Hold the flywheel with a suitable tool A remove the fly wheel bolt B and washer e Remove the bracket C e Using a suitable flywheel puller A remo
50. d take care that there is no sparks or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean the carburetors CAUTION Do not use compressed air on an assembled carbu retor or the floats may be crushed by the pressure Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carbure tor with a cleaning solution This will prevent dam age to or deterioration of the parts The carburetor body has plastic parts that can not be removed Do not use a strong carburetor cleaning solution which could attack these parts instead use a mild high flash point cleaning solu tion safe for plastic parts Do not use wire or any other hard instrument to clean carburetor parts especially jets as they may be damaged e Disassemble the carburetor see Carburetor Disassem bly Assembly e Immerse all the carburetor metal parts 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 see Carburetor Disassem bly Assembly Carburetor FUEL SYSTEM 3 29 Carburetor Inspection A WARNING Gasoli
51. d 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 lt AIR wy MIXTURE KC05185BW3 C 3 16 FUEL SYSTEM Carburetor FR and FS Models The main system of the carburetor consists of the main jet A main nozzle B and the main air passage C main air jet D The main system meters fuel to the engine dur ing moderate to heavy load conditions Fuel flows through the main jet and into the main nozzle where it is joined by air from the mai
52. d re move the spark plug f xIf the plug is oily or has carbon built up on it clean the ff plug using a high flash point solvent and a wire brush or L Py other suitable tools EE N 5555 x If the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug with a new one Use the standard spark plug or its equivalent Insulator A Center Electrode B Plug Gap C Side Electrode D 272220 lt lt GP10012381 Spark Plug Gap Inspection e Measure the gap with a wire type thickness gauge x If the gap is not correct carefully bend the side electrode with a suitable tool to obtain the correct gap Spark Plug Gap Standard 0 7 0 8 mm 0 028 0 031 in FUEL SYSTEM 3 1 Fuel System Table of Contents WE 3 2 eene de 3 8 Governor Link Mechanism t eee ae E tes e a a RN 3 10 Control Panel Assembly Removal pp 3 10 Control Panel Assembly Installation ane E 3 10 Governor Arm Removal 99999 3 11 Governor Arm Installation 3 12 Governor Assembly Removal 3 12 Governor Assembly Installation pp 3 13 Governor Assembly Inspection pp 3 13 Governor Shaft Removal orent ret ensi eec ER 3 13 Governor Shaft Installation 3 13
53. dels e Remove Control Panel and Inlet Pipe Mounting Bolt A Carburetor and Inlet Pipe Mounting Nut B Control Panel Mounting Bolt C Choke Spring D Control Panel Assembly E Governor Spring F 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 xIf any part is worn or damaged replace the control panel assembly with a new one FX Models C FR and FS Models D FX Models e Install the governor spring A control panel assembly B and choke spring C e Tighten Torque Control Panel Mounting Bolt D 5 9 N m 0 60 kgf m 52 in Ib Carburetor and Inlet Pipe Mounting Nut E 5 9 N m 0 60 kgf m 52 in Ib Carburetor and Inlet Pipe Mounting Bolt F 5 9 N m 0 60 kgf m 52 in Ib e After installation adjust the low idle speed and high idle speed to the specifications see Low High Idle Speed Ad justment in the Periodic Maintenance chapter K041 10 Governor Link Mechanism FUEL SYSTEM 3 11 FR and FS Models e Install the governor spring A control panel assembly B and choke spring C e Tighten Torque Control Panel Mounting Bolt D 5 9 N m 0 60 kgf m 52 in Ib Carburetor and Inlet Pipe Mounting Nut E 5 9 N m 0 60 kgf m 52 in Ib Control Panel and Inlet Pipe Mounting Bolt F 5 9 N m 0 60 kgf m 52 in Ib e After installation adjust t
54. dle rpm 1 450 r min rpm e Release the throttle lever e Loosen the locknut A e Adjustthe low idle speed set screw B on the control plate to obtain the specified governor low idle speed Low Idle Speed Governor idle rpm 1 550 r min rpm e Tighten the locknut High Idle Speed Adjustment NOTE OHigh idle speed adjustment should be made after the idle speed adjustment is performed CAUTION Do not adjust high idle speed with the air cleaner removed e Start and warm up the engine thoroughly 2 8 PERIODIC MAINTENANCE Periodic Maintenance Procedures A WARNING Always keep your hands clear of the moving parts e Loosen the locknut A and unscrew the high idle set screw B few turns e Move the throttle lever on dash to obtain the specified high idle speed and leave it there High Idle Speed 3 600 r min rpm e Turn the high idle set screw so that the end of it just touches the speed control lever C and tighten the lock nut e Check the idle speed and readjust the idle speed if nec essary CAUTION Be sure to make the idle and fast idle speeds re spectively correspond to those of the equipment Fuel System Cleanliness Inspection A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the engine switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this incl
55. e Loosen the clamp A e Remove Bolt B Holder Bracket C e Take out the air cleaner body D together with the inlet hose E 3 38 FUEL SYSTEM Air Cleaner e Remove Bolts A Bracket B Air Cleaner Body and Bracket Installation FX Models e Install the air cleaner bracket A e Tighten Torque Air Cleaner Bracket Mounting Bolts B 5 9 N m 0 60 kgf m 52 in Ib e Set the air cleaner body A onto the lower bracket so that the air inlet duct B is facing upward Install the inlet hose and tighten the clamp D e Install the upper bracket E e Tighten Torque Air Cleaner Holder Bracket Bolts F 5 9 N m 0 60 kgf m 52 in lb Air Cleaner Housing Cap and Body Inspection FX Models e Refer to the Air Cleaner Housing Cap and Body Inspec tion in the Periodic Maintenance chapter COOLING SYSTEM 4 1 Cooling System Table of Contents Exploded WE 4 2 Cooling Fan EE 4 4 Cooling ee 4 4 Cooling Fan Installation io beet tcr oe beta tti edet be edo io Aert 4 4 Cooling Fam INSPSCHON EE 4 4 Engine lee e Ln 4 5 Ginen 4 5 Ginen et Ria GE EE 4 5 4 2 COOLING SYSTEM Exploded View cll Hi ERT COOLING SYSTEM 4 3 Exploded View Fastener 1 Cooling Fan Plate Mounting Bolts 8 8 0 90 78 in lb 2 Cooling Fan Sc
56. e Measure the clearance between the top and second rings and their grooves using a thickness gauge A as shown x If the piston ring groove clearance is greater than the ser vice limit replace the piston with a new one Piston Ring Groove Clearance Service Limit Top 0 19 mm 0 0075 in Second 0 20 mm 0 0079 in NOTE OThe oil ring is a three piece assembled ring It is difficult to measure the ring groove clearance and thickness visually inspect only e Measure the piston ring thickness A OUse a micrometer to measure at several points around the rings x If any of the measurement are less than the service limit replace the entire set of rings with new ones Piston Ring Thickness Service Limit Top 1 1 mm 0 043 in Second 1 1 mm 0 043 in NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston with a new one KEG6038BS1 C KE08039BS1 C KEG6010BS1 C ENGINE TOP END 5 21 Cylinder Piston Piston Ring End Gap e Remove the piston rings see Piston Removal e Push each ring one at a time in the cylinder bore to a point close to the bottom of the cylinder bore OUse the piston to push it in to be sure it is square e Measure the gap A between the ends of the ring B with a thickness gauge x If the end gap of any ring is greater than the service limit rep
57. e 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 2009 Kawasaki Heavy Industries Ltd First Edition 1 Jan 9 2009 K BBDC BDC BTDC C DC F ft P LIST OF ABBREVIATIONS ampere s after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree s Celsius direct current farad s degree s Fahrenheit foot feet gram s hour s liter s psi rpm TDC TIR pound s meter s minute s newton s pascal s horsepower pound s per square inch revolution revolution s per minute top dead center total indicator reading volt s watt s ohm s EMISSION CONTROL INFORMATION To protect the environment in which we alllive Kawasaki has incorporated crankcase emission 1 exhaust emission 2 control systems 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 eli
58. e valve seating Valve clearance Piston cylinder wear piston seizure Piston ring piston ring groove Qa 5 8 ENGINE TOP END Cylinder Head Cylinder Head Assembly Removal e Remove Inlet Manifold see Inlet Manifold Removal in the Fuel System chapter Spark Plugs see Spark Plug Removal in the Electrical System chapter e Unscrew the rocker cover bolts in the order shown 1 to 5 e Remove the cover A and the gasket e When removing the 1 2 cylinder head set each pis ton at the top dead center T D C A of the compression stroke e Remove Rocker Arm see Valve Mechanism Removal Installa tion Push Rod see Push Rod Removal Rocker Arm Bracket see Valve Mechanism Removal In stallation e Loosen the cylinder head bolts 1 4 turn in the sequence as shown in the figure CAUTION If the above procedure is not followed the cylinder head may be warped during removal e Repeat the sequence until all bolts are removed and lift off the cylinder head assembly NOTE OMark the push rods and rocker arms 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 oylin ders e Replace the gaskets with new ones e Install the dowel pins A m ENGINE TOP END 5 9 Cylinder Head e Set each piston at the T D C A of the compressio
59. eaner elements Do not oil air cleaner elements Do not use pressurized air to clean air cleaner elements FR Models e Remove the paper element see Air Cleaner Element Re moval e Clean the paper element A by tapping it gently on a flat surface to remove dust If the element is very dirty re place it with a new one FS Models e Remove the foam and paper elements see Air Cleaner Element Removal e Clean the foam element A in a bath of detergent and water and let the element air dry thoroughly e Clean the paper element B by tapping it gently on a flat surface to remove dust If the element is very dirty re place it with a new one 2 10 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Cleaner Housing Cap and Body Inspection FX Models e Remove Elements see Element Removal in the Fuel System chapter Air Cleaner Housing see Air Cleaner Body and Bracket Removal in the Fuel System chapter e Clean the housing with detergent and water and dry the housing thoroughly e Check the housing for deformation or other damage OSeal the housing well and permit only filtered air to reach the carburetor x If the housing is damaged replace the housing with a new one e Check that no foreign material is obstructing the air pas sage Engine Top End Cylinder Head Cleaning e Scrape the carbon deposits from the cylinder head and the exhaust port with a suitable tool A OTo avoid gouging
60. ee Exploded View 1 Pilot Screw Plug 2 Pilot Screw 3 Spring 4 Low Idle Speed Screw 5 Spring 6 Screws 7 Throttle Valve 8 Screw 9 Throttle Lever 10 Throttle Shaft 11 Dust Seal 12 Choke Valve 13 Choke Shaft 14 Dust Seal 15 Solenoid Valve 16 Gasket 17 Float Chamber 18 Gasket 19 Float Pin KC05190BS3 20 Float 21 Main Jet 22 Main Nozzle 23 Float Valve FUEL SYSTEM 3 27 Carburetor FR730V and FS730V Models e Refer to the illustration shown for disassembly and as sembly e There are several passage plugs ball plugs in the car buretor body Do not remove e Before disassembly mark the out side of choke and throt tle valves for assembling them 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 into the carburetor body e Assemble carburetor parts with recommended tightening torque see Exploded View 1 Pilot Screw Plug 2 Pilot Screw 3 Spring 4 Low Idle Speed Screw 5 Spring 6 Screws 7 Throttle Valve 8 Throttle Shaft 9 Dust Seal 10 Choke Valve 11 Choke Shaft 12 Dust Seal 13 Solenoid Valve 14 Gasket 15 Float Chamber 16 Gasket 17 Float Pin 18 Float 19 Main Jet 005196883 20 Main Nozzle 21 Float Valve 3 28 FUEL SYSTEM Carburetor Carburetor Cleaning A WARNING Clean the carburetor in a well ventilated area an
61. ent is less than the service limit replace the piston with a new one Piston Diameter Service Limit 77 79 mm 3 063 in Cylinder Inside Diameter e Clean and measure the cylinder inside diameter OUse a cylinder gauge to measure front to back and side to side at the points as shown in the figure xIf any of the cylinder inside diameter measured value is greater than the service limit replace the crankcase with a new one 10 mm 0 39 in A 40 mm 1 6 in B 25 mm 0 98 in C Cylinder Inside Diameter Standard Standard Cylinder 77 98 78 00 mm 3 070 3 071 in 0 50 mm Oversize 78 48 78 50 mm 3 090 3 091 in Service Limit Standard Cylinder 78 08 mm 3 074 in 0 50 mm Oversize 78 58 mm 3 094 in Cylinder Bore Out Round Service Limit 0 05 mm 0 002 in Cylinder Boring and Honing Always resize to exactly 0 5 mm 0 02 in over the stan dard 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 manufacturer to produce correct cylinder wall finish Machine bore first the bore diameters should be shown in the table Final Boring Bore Diameter Oversize Final Boring Bore Diameter 0 50 mm 78 46 78 48 mm 3 089 3 090 in Final Bore Diameter Oversize Final Bore
62. epair the seat KM07018BS1 C 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Coat the seat with machinist s dye e Fit a 45 cutter A to the holder and slide it into the valve guide OResurface the valve seat with a 45 cutter removing only enough material to produce a smooth and concentric seat CAUTION Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced Do not turn the cutter counterclockwise or drop it against the seat or it will be dulled e Use a 32 seat cutter A to narrow the seat width to the standard width OTurn the seat cutter one turn at a time while pressing down very lightly Check the seat width after each turn CAUTION The 32 cutter removes material very quickly Check the seat width frequently to prevent over grinding NOTE OKeep the seat width as close as possible to the standard width Make a light contact on the valve seat with the 45 cutter to remove any possible burrs at the edge of the seat e After resurfacing the seat inspect for even valve seating OApply a machinists 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 cente
63. ernor shaft moves freely in its operating range NOTE Olf the oil seal is removed oil seal is put on after shaft is installed see Crankcase Cover Installation in the Camshaft Crankshaft chapter 3 14 FUEL SYSTEM Carburetor Fuel and Air Flow FX Models The main system of the carburetor consists of the main jet A valve seat B main nozzle C and the main air passage D main air jet E The main system meters fuel to the engine during moderate to heavy load conditions Fuel flows through the main jet and into the main nozzle where it is joined by air from the main air passage main air orifice The resulting 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 lt AIR Su MIXTURE mm FUEL KC05184BW3 C FUEL SYSTEM 3 15 Carburetor The pilot system includes the pilot jet F pilot screw Idle mixture screw pilot outlet and the bypass holes I The pilot system meters the fuel air mixture while the engine is idling and running under a light load Under these conditions there is very little air flow through the carburetor bore so little that it is not enough to draw fuel through the main system of the carburetor and atomize it Instead the fuel is drawn through the pilot system since the nearly closed throttle valve J causes high speed air flow past the pilot outlet an
64. eter is less than the service limit replace the armature with a new one Commutator Outside Diameter Standard FX Models 28 0 mm 1 10 in FR and FS Models Service Limit FX Models 27 0 mm 1 06 in FR and FS Models 31 369 mm 1 235 in GP11080781 8 14 STARTER SYSTEM Electric Starter System e Support the armature in an alignment jig at each end of the shaft as shown Position a dial indicator perpendicular to the commutator e Rotate the armature slowly and read the commutator runout x If runout is more than the service limit replace the arma ture with a new one Commutator Runout Service Limit FX Models 0 4 mm 0 016 in FR and FS Models 0 043 mm 0 0017 in e Measure the armature winding resistance OSet the multimeter selector switch to the R x 1 O position and check the resistance between each segment and all the others xIf the resistance it too high or even infinite the armature winding has an open circuit Replace the starter motor Armature Winding Resistance Close 0 e Set the multimeter selector switch to the R x 1 position and measure the resistance between the commutator and the armature shaft lf the resistance is less than infinite the armature is shorted Commutator to Shaft Resistance e Test the armature winding for shorts OPlace the armature on a growler A OHold a thin metal strip e g hack saw blade on top of the armature OT
65. etor e Inspect the float valve for excessive wear or damage The tip should be smooth without any grooves scratches or tears The rod atthe other end of the needle should move smoothly when push in and released Good A Not Good B xIf either the needle or the seat is worn or damaged re place the float assembly and carburetor body as a set with a new one e Inspect the tapered portion A of the pilot screw B for wear or damage x If the pilot screw is worn or damaged on the tapered por tion replace it with a new one e Check the spring for weakened condition replace it with a new one if necessary Other than FX Models FX Models C FR and FS Models D Fuel Shut Off Solenoid Valve Test e Unscrew the fuel shut off valve A and remove it e Connect a 12 VDC source to the solenoid as shown in the figure x If the actuated solenoid plunger Needle Valve does not pop out when the Test Voltage is applied replace it with a new one NOTE Olf necessary push the plunger slightly for the plunger to withdraw KCGO5011BS1 C KC05181BS1 C KGO5192BS1 C KC05178BS1 C FUEL SYSTEM 3 31 Inlet Manifold Inlet Manifold Removal e Remove the engine shroud see Engine Shroud Removal T gd in the Cooling System chapter Se e Unscrew the inlet manifold mounting bolts A e Remove the inlet manifold B and gaskets FX Models C FR and FS Models D Inlet Manifold Insta
66. fler FR Models 40 0 kg 88 2 Ib FS Models 41 0 kg 90 4 Ib FX Models 46 0 kg 101 4 Ib Specifications are subject to change without notice PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart Torque and Locking ee Special Tools Periodic Maintenance Drocecdures HI i secos EE Low Idle Speed Adjustment High Idle Speed Adjustment oco oar ori oor ee ot Fuel System Cleanliness 2 Element Cleaning and Inspection eau oai Ln tm ie e ul cte eee de bene nene n Air Cleaner Housing Cap and Body Engine Jop End Cylinder Head Cleaning Valve Clearance Inspection Valve Clearance Adjustment EE Valve Seat Inspection Valve Seat Repair Lubrication System Engine Oil Level Inspection Engine Oil Change Oil Filter Replacement Electrical System Spark Plug Cleaning and In Spark Plug Gap Inspection 2 2 2 3 2 5 2 6 2 7 2 7 2 7 2 7 2 8 2 10 2 10 2 10 2 10 2 11 2 12 2 12 2 15 2 15 2 15 2 16 2 17 2 17 2 17 2 2 PERIODIC MAINTENANCE Periodic Maintenance Chart To ensure
67. follows Replacing with new one Olnstall the second ring so that the white stripe A is on the right side of the end gap Reassembling the ring in use Olnstall the second ring so that the notched edge B faces upward e Install the top ring e The rings should turn freely in the grooves Piston Head C Top Ring D Second Ring E e Align the piston and rings with the piston ring end gap as shown in the figure Arrow Match Marks A Top Ring End Gap Upper Steel Rail End Gap B 45 C Second Ring End Gap Lower Steel Rail End Gap D GE160606S1 C KE06045BS1 KE08121BS1 60 KE08105BS1 C 5 18 ENGINE END Cylinder Piston e Apply engine oil to the piston pins e Assemble the pistons onto the connecting rods as follow ONo 1 Cylinder Piston align the arrow mark on the piston head with opposite Mark on the connecting rod to face the flywheel side ONo 2 Cylinder Piston align the arrow mark on the piston crown with the mark on the connecting rod OBoth marks must face the flywheel side No 1 cylinder Piston A No 2 cylinder Piston B Arrow Marks C K Mark D Opposite K Mark E e Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the notch B in the edge of the piston pin hole OWhen installing a piston pin snap ring compress it only enough to install it and no more CAUTION
68. fuel air mixture allowed through the pilot outlet but does not me ter the bypass holes A moderate amount of air comes in around the throttle valve at idle so adjusting the pilot screw changes the fuel air ratio Turning the pilot screw idle mix ture screw out counterclockwise enriches the mixture turning it in clockwise leans the mixture Main Fuel Flow Pilot Fuel Flow gt Main System Fuel and Air Supply KCO5186BS2 Pilot System Fuel and Air Supply Fuel Float Main Tank Chamber Jet KC05187BS2 C Carburetor FUEL SYSTEM 3 17 Fuel Shut Off Solenoid Valve To avoid after firing when stopping the engine a solenoid actuated fuel shut off solenoid valve A is installed in the carburetor bowl The valve shuts off the fuel supply to the main jets B simultaneously when the switch key turned to the OFF position The valve opens automatically when the switch key is turned to the Run position FX Models C FR and FS Models D Low Idle Speed Adjustment e Refer to the Low Idle Speed Adjustment in the Periodic Maintenance chapter High Idle Speed Adjustment e Refer to the High Idle Speed Adjustment in the Periodic Maintenance chapter High Altitude Operation At high altitude the standard carburetor air fuel mixture will be excessively rich Performance will decrease and fuel consumption will increase High altitude performance can be improved by i
69. he START position and read the tester xIf the tester reads battery voltage the circuit is good xIf the tester reads much less than battery voltage or no voltage at all either the wiring or the engine switch is bad Check the engine switch or the wiring for damaged or broken wires and replace as required Electric Starter System STARTER SYSTEM 8 7 Starter Motor Test NOTE OAlways inspect the Starter Solenoid and Circuit Test section before starting following procedures e Remove the starter motor see Starter Motor Removal e Hold the starter motor with a vice CAUTION Be careful not to deform the starter motor body when holding it with a vice e Connect the first jumper cable to the battery terminal and the other end of the cable to the starter motor terminal on the solenoid as shown in the figure e Connect the second jumper cable to the battery termi nal e Touch the switch intermittently for one second intervals e The pinion should rotate freely x If the pinion does not rotate freely replace the starter mo tor Starter Motor Disassembly FX Models Loosen the terminal nut e Remove the lead B from the starter motor to the sole noid Unscrew the mounting nuts A and remove the solenoid assembly B e Remove the through bolts A and end cover B OSlide the lead grommet C to outside 8 8 STARTER SYSTEM Electric Sta
70. he crankcase e Remove the tappets A and mark them so they can be installed in their original positions during assembly Camshaft Tappet Installation e Apply engine oil to the followings Tappet Journal Camshaft Journal Cam Lobe Surface Camshaft Gear e Align the punch marks A on the crankshaft gear and camshaft gear Install the removed parts see appropriate chapters Camshaft Disassembly e Remove Governor Assembly see Governor Assembly Removal in the Fuel System chapter Spring A ODo not remove the ACR automatic compression release weight B CAMSHAFT CRANKSHAFT 7 15 Camshaft Tappet Camshaft Assembly e Install the governor assembly see Governor Assembly Installation in the Fuel System chapter e After assembling the camshaft check the following items OThe governor plate A must move freely OWhile shaking the camshaft check if the ACR weight B swings smoothly Camshaft Inspection e Check the camshaft gear A for pitting fatigue cracks burrs or any evidence of improper tooth contact Replace the camshaft with a new if necessary e Check the top of the cam lobes B for wear burrs or un even contact Replace the camshaft with a new one if necessary Camshaft Bearing Journal Wear Measure the height A of each cam lobe x lf the cam height is less than the service limit for either lobe replace the camshaft with a new one Cam Lobe Height Service L
71. he cylinder head with a suitable tool before the piston and connecting rod are pulled out e Push the connecting rod end into the cylinder and pull the piston and connecting rod out of the cylinder CAUTION Note the location of the arrow match mark A on the piston head in relation to Mark B on the connecting rod No 1 cylinder K Mark on the connecting rod is face to face with No 2 cylinder K Mark on the con necting rod Keep parts together as a set e Remove one of the piston pin snap rings A with needle nose pliers B Remove the piston by pushing the piston pin A to the direction from which the snap ring was removed e Remove the piston from the connecting rod KE068140 Cylinder Piston ENGINE TOP END 5 17 eRemove the top and second rings with piston ring pliers Special Tool Piston Ring Pliers 57001 115 e If the special tool is not available carefully spread the ring opening with your thumbs then push up to the opposite side of the ring A to remove it e Remove the 3 piece oil ring with your thumbs in the same manner Piston Installation e Install the expander A in the piston oil ring groove so that the expander ends B touch together never overlap them e Install the upper and lower steel rails There is no UP or Down to the rails They can be installed either way e Do not mix up the top and second rings e Install the second ring as
72. he low idle speed and high idle speed to the specifications see Low High Idle Speed Ad justment in the Periodic Maintenance chapter Governor Arm Removal e Remove the control panel assembly see Control Panel Assembly Removal e Unhook the throttle link rod spring A end loop and clear the throttle link rod lower end B FX Models C FR and FS Models D e Loosen the clamp nut A and take off the governor arm B 3 12 FUEL SYSTEM Governor Link Mechanism e Remove the bolt A to separate the governor arms B Governor Arm Installation e Install the inside governor arm A onto the governor shaft B e Be sure the link spring C around the throttle link rod D is in place and that it pulls the outside governor arm E and throttle lever F each other e Tighten Torque Governor Arm Clamp Nut G 7 8 N m 0 80 kgf m 69 in Ib e Turn the top end of the governor arm counterclockwise to fully open the carburetor throttle valve and hold it there e Turn the inside governor arm counterclockwise fully to the end of its travel e Tighten Torque Governor Arm Joint Bolt 5 9 N m 0 60 kgf m 52 in Ib OGovernor arm joint bolt is left hand threads e Install the control panel assembly see Control Panel As sembly Installation Governor Assembly Removal e Remove Camshaft see Camshaft Tappet Removal in the Camshaft Crankshaft chapter Pin A Washer 30 B Snap Rings C Was
73. her 42 D Sleeve E Governor Plate F Steel Balls G Ball Guide H Ball Plate 1 0048103 P KC04052BS2 C Governor Link Mechanism FUEL SYSTEM 3 13 Governor Assembly Installation e Fit the snap ring into the groove securely e Turn the governor plate by hand and check that the steel balls and governor plate operate freely e Replace the spring pin A with a new one e Be sure to install the washer B and pin 2 0 2 3 mm 0 079 0 091 in C Governor Assembly Inspection e Visually check all governor parts for wear or damage x If any parts are worn or damaged replace them with new ones Governor Shaft Removal e Remove the crankcase cover see Crankcase Cover Re moval in the Camshaft Crankcase chapter e Unscrew the governor shaft plate screws A and remove the governor shaft plate B e Pull out the governor shaft C outside NOTE ORemove the governor shaft only if the replacement of the governor shaft is necessary e Replace the oil seal with a new one if the lip shows signs of leakage or it has been damaged see Crankcase Cover Assembly in the Camshaft Crankshaft chapter Governor Shaft Installation e Apply engine oil to the governor shaft e Insert the governor shaft A into the crankcase cover e Install the governor shaft plate B to the shaft e Tighten Torque Governor Shaft Plate Screws C 2 0 N m 0 20 kgf m 18 in Ib e Checkthat the gov
74. ication system Oil Pressure 294 to 588 kPa 43 to 85 psi Measurement Condition Engine Oil Temperature 50 60 C 122 144 F Engine Speed 3 200 r min rpm e Stop the engine e Remove the oil pressure gauge and adapter A WARNING Take care against burns form hot engine oil that will drain through the oil passage when the gauge adapter is removed e Apply a non parmanent locking agent to the oil passage plug and tighten it Torque Oil Passage Plug 3 9 N m 0 40 kgf m 35 in Ib LUBRICATION SYSTEM 6 9 Oil Pump Relief Valve Oil Pump Relief Valve Removal e Remove Crankcase Cover see Crankcase Cover Removal in the Camshaft Crankshaft chapter Governor Shaft see Governor Shaft Removal in the Fuel System chapter Bolts A Pump Cover Plate B e Remove Inner Rotor A Outer Rotor B Spring C Relief Valve Ball D Oil Pump Relief Valve Installation e Fill the rotor housing with engine oil for initial lubrication e Install the outer A and inner rotor B OAlign the inner rotor groove C to the center of the crankcase cover as shown in the figure e Install the relief valve ball and spring in position e Install the pump cover plate e Tighten Torque Oil Pump Cover Plate Bolts 5 9 N m 0 60 kgf m 52 Oil Pump Relief Valve Inspection e Remove the pump cover plate see Oil Pump Relief Valve Removal e Visually inspect the pump gear outer and inner rotor
75. il Air Gap Primary Winding Resistance Secondary Winding Resistance Spark Plug Plug Gap 14 1 V DC 0 1 0 14 O 26 34 V AC 3 000 rpm in the text 0 2 0 4 mm 0 008 0 016 in in the text in the text BPR4ES 0 7 0 8 mm 0 028 0 031 in 15 V DC 26 V AC 3 000 rpm ELECTRICAL SYSTEM 9 5 Special Tool Hand Tester 57001 1394 9 6 ELECTRICAL SYSTEM Wiring Dagram FX Models Note Portion surrounded by shows KHI procurement parts ark Plugs m AE 2 Starter P Voltage Regulator Color Code Battery START ototo de KH040388W4 C ELECTRICAL SYSTEM 9 7 Wiring Dagram FR Models Note Portion surrounded by shows KHI procurement parts k PI Carburetor Starter CEA ES N S Be E 4527 ANON i SH Se Er e SS T SIS L Color Code Battery START off pi KH040398W4 C 9 8 ELECTRICAL SYSTEM Wiring Dagram FS Models Note Portion surrounded by shows KHI procurement parts park Plugs Carburetor Starter SE GE del ech D 55 A 4 VS RY EL NS Color Code Battery KH040408W4 C Precautions ELECTRICAL SYSTEM 9 9 There are a n
76. imit Inlet 29 36 mm 1 156 in Exhaust 29 36 mm 1 156 in Measure both camshaft journal diameter A at several points around the journal circumference xIf the journal diameter is less than the service limit re place the camshaft with a new one Camshaft Journal Diameter Service Limit PTO Side 15 99 mm 0 630 in Flywheel Side 15 99 mm 0 630 in e Measure the inside diameter A of the camshaft insert on the crankcase at several points xIf the inside diameter is more than the service limit re place the crankcase with a new one Camshaft Bearing Inside Diameter Crankcase Service Limit 16 119 mm 0 6346 in 6 11012251 60 7 16 CAMSHAFT CRANKSHAFT Camshaft Tappet e Measure the inside diameter A of the camshaft insert on the crankcase cover at several points xIf the inside diameter is more than the service limit re place the crankcase cover with a new one Camshaft Bearing Inside Diameter Crankcase Cover Service Limit 16 119 mm 0 6346 in CAMSHAFT CRANKSHAFT 7 17 Crankshaft Connecting Rod Connecting Rod Removal e Remove the piston see Piston Removal in the Engine Top End chapter Connecting Rod Installation e Install the piston see Piston Installation in the Engine Top End chapter Crankshaft Removal e Remove Camshaft see Camshaft Tappet Removal Connecting Rod and Pistons see Piston Removal in the Engine Top End chapter e Pull the crankshaft
77. it Cylinder Head Cylinder Compression MIN Cylinder Head Warp 440 kPa 64 psi Engine Oil Temperature 50 60 122 144 F Cranking Speed 450 rpm 5 Seconds 0 05 mm 0 002 in Valves Valve Head Thickness Inlet Exhaust Valve Stem Runout Inlet Exhaust Valve Stem Diameter Inlet Exhaust Valve Guide Inside Diameter Inlet Exhaust Valve Spring Free Length Inlet Exhaust Rocker Arm Push Rod Runout Inlet Exhaust Rocker Shaft Outside Diameter Inlet Exhaust Rocker Arm Inside Diameter Inlet Exhaust 0 3 mm 0 012 in TIR 0 05 mm 0 002 in 5 95 mm 0 234 in 5 93 mm 0 233 in 6 08 mm 0 239 in 31 0 mm 1 22 in TIR 0 5 mm 0 02 in 10 91 mm 0 430 in 11 13 mm 0 438 in Cylinder Piston Piston Diameter Piston Ring Groove Clearance Top Second Piston Ring Thickness Top Second Piston Ring End Gap Top Second Oil Piston Pin Outside Diameter Piston Pin Hole Inside Diameter Connecting Rod Small End Inside Diameter Cylinder Inside Diameter Standard Cylinder 0 50 mm Oversize Cylinder Cylinder Inside Diameter Out Round 77 79 mm 3 063 in 0 19 mm 0 0075 in 0 20 mm 0 0079 in 1 1 mm 0 043 in 1 1 mm 0 043 in 0 6 mm 0 024 in 0 9 mm 0 035 in 1 1 mm 0 043 in 16 96 mm 0 668 in 17 08 mm 0 672 in 17 06 mm 0 672 in 78 08 mm 3 074 in 78 58 mm 3 094 in 0 05 mm 0 002 in Specifications ENGINE TOP
78. ith a new one Unregulated Stator Output e Disconnect the stator coil lead connector A e Connect AC voltmeter to the stator pins B e Start the engine Run the engine at the 3 000 rpm speed e Voltage reading should be minimum 26 V AC 3 000 rpm xIf the AC voltage reading is less than the specification replace the stator with a new one Unregulated Stator Output MIN 26 V AC 3 000 rpm Regulator Removal FX Models e Remove Stator Coil Lead Connector A Regulator Mounting Screws B Regulator C FS Models e Remove Stator Coil Lead Connector A Regulator Mounting Screws B Ground Lead C Regulator D KH07056BS1 C 9 16 ELECTRICAL SYSTEM Charging System Regulator Installation FX Models e Install the regulator A e Tighten the regulator mounting screws B e Apply dielectric grease to the regulator terminals C e Connect the stator coil lead connector D FS Models e Install Regulator A Ground Lead B e Tighten the regulator mounting screws C e Apply dielectric grease to the regulator terminals D e Connect the stator coil lead connector E KH07057BS1 C Regulator Resistance FS and FX Models e Remove the regulator see Regulator Removal e Set the KAWASAKI Hand Tester selector switch to the R x 100 O position e Connect the test leads to the points shown on the chart and read the resistance Without Charging Monitor Type
79. ith a new one Connecting Rod Big End Width Service Limit 22 05 mm 0 868 in KG08035BS1 C KG08036BS1 C CAMSHAFT CRANKSHAFT 7 19 Crankshaft Connecting Rod Measure the crankpin width A with a dial caliper x If the crankpin width is more than the service limit replace the crankshaft with a new one Crankpin Width Service Limit 44 7 mm 1 76 in Connecting Rod Big End Bearing Crankpin Wear e Apply a light film of engine oil on the threads of the cap bolts e Install the cap bolts and tighten the bolts to the speci fied torque see Piston Installation in the Engine Top End chapter e Measure the inside diameter A of big end at several points with a telescoping gauge or inside micrometer xIf the inside diameter is more than the service limit re place the connecting rod with a new one Connecting Rod Big End Inside Diameter Service Limit 40 04 mm 1 58 in Measure the crankpin outside diameter A OUse a micrometer to measure several points around the crankpin circumference xIf the crankpin diameter is less than the service limit re place the crankshaft with a new one Crankpin Outside Diameter Service Limit 39 94 mm 1 57 in Crankshaft Runout e Measure the crankshaft runout OSet the crankshaft in a flywheel alignment jig A or on V blocks gauge OSet a dial gauge B against both bearing journals OTurn the crankshaft slowly to measure the runout
80. izure e n case of seizure remove the pistons see Piston Re moval e Visually inspect the cylinder and pistons for damage xIf there is only light damage repair the damaged piston surface with 400 emery cloth Remove the small alu minum deposits from the cylinder with 400 emery cloth or light honing xIf the damage is severe replace the crankcase and pis tons Piston Cleaning e Remove the piston and piston rings see Piston Re moval CAUTION Never clean the piston head with the engine assem bled Carbon particles will fall between the piston and cylinder and damage the crankshaft bearings e Scrape the carbon off the piston head e Use the scraping tools A carefully Do not gouge the pis ton head To avoid gouging use scrapers that are made of a material that will not cause damage KE08119BS2 C KE06037BS1 5 20 ENGINE END Cylinder Piston e Clean the piston ring grooves A with a broken piston ring or other suitable tools CAUTION Be careful not to widen the ring grooves Damaged ring grooves will require piston replacement Piston Ring and Ring Groove Wear e Clean the piston see Piston Cleaning e Visually inspect the piston rings and ring grooves x If the piston rings are worn unevenly or damaged replace them with new ones xIf the ring grooves are worn unevenly or damaged re place both the piston and the piston rings with new ones
81. lace the entire set of rings with new ones f KE08124BS1 C Piston Ring End Gap Service Limit Top 0 6 mm 0 024 in Second 0 9 mm 0 035 in Oil 1 1 mm 0 043 in Piston Pin Piston Pin Hole and Connecting Rod Wear e Remove the piston pin see Piston Removal e Measure the outside diameter of the piston pin with a mi crometer at several points xIf the outside diameter is less than service limit replace the piston pin with a new one Piston Pin Outside Diameter Service Limit 16 96 mm 0 668 in KE06012BS1 EI e Measure the inside diameter A of the piston pin hole at several points on both side Use a dial bore gauge x If the inside diameter is greater than the service limit re place the piston with a new one Piston Pin Hole Inside Diameter Service Limit 17 08 mm 0 672 in P KE08117BS1 C e Measure the inside diameter A of the connecting rod small end at several points Use a dial bore gauge xIf the inside diameter is more than the service limit re place the connecting rod with a new one Connecting Rod Small End Inside Diameter Service Limit 17 06 mm 0 672 in KE08120BS1 C 5 22 ENGINE END Cylinder Piston Piston Diameter e Measure the outside diameter A of the piston 11 mm 0 43 in B up from the bottom of the piston at a right angle to the direction of the piston pin hole x If the measurem
82. lation Cleaning and Inspection e Clean the oil screen A with high flash point solvent and A remove any particles stuck to it A WARNING Clean the screen in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents OWhile cleaning the screen check for any metal particles that might indicate internal engine damage e Check the screen carefully for any damage holes and broken wire x If the screen is damaged replace it with a new one CAMSHAFT CRANKSHAFT 7 1 Camshaft Crankshaft Table of Contents leie ie iL 7 2 eigene e 7 4 DPSClAl Le e IEEE 7 5 EE 7 6 Crankcase Cover Removal 7 6 Crankcase Cover Disasseribly toI e te eoe taa da EN Eder eck 7 6 Grankcase Cover d TEE 7 7 Crankcase Cover Installation Ne 7 7 Crankcase Cover Inspechon 7 8 Crankcase Disassembly EE 7 8 Grankcase ASSEMIDIY Beet SE 7 8 Crankcase 7 9 Crankcase and Crankcase Cover Cleaning nns 7 9 OTT DLL DRE 7 10 Breather Valve 7 12 Breather Valve Installation 7 12 Breather Valve Inspection 7 13 Breather Pipe Removal utei ebo
83. llation e Replace the inlet manifold gaskets A with new ones e Clean the mating surfaces of the cylinders and Inlet man ifolds e Install the inlet manifold gaskets so that the hole B of the gaskets fit the projection C of the cylinder head e Install the inlet manifold e Tighten the inlet manifold mounting bolts following the tightening sequence Torque Inlet Manifold Mounting Bolts 5 9 N m 0 60 kgf m 52 in lb FX Models A FR and FS Models B 7 A 4 dee Ow e Install the removed parts see appropriate chapters 3 32 FUEL SYSTEM Inlet Manifold Inlet Manifold Inspection e Inspect the intake manifold for cracks or porous casting e Cracks not visible to the eye may be detected by using a metal crack detection system Visual color check com monly found at automotive parts store xIf a crack is present in the inlet manifold replace it e Inspect the gasket surfaces for burrs and nicks Fuel Pump Fuel Filter FUEL SYSTEM 3 33 The diaphragm in the fuel pump operates by the pulse generated in the crankcase and the fuel pump supplies fuel to the carburetor The fuel pump disassembly is not recommended if any damage for the pump is noticed replace it with a new one Fuel Pump Removal e Remove Fuel Tubes A Pulse Tube B Screws C Fuel Pump D Fuel Pump Installation Connect the fuel tubes A and pulse tube B fully e Tighten the fuel pump mounting screws C F
84. llow the procedures in this manual care fully Don t take shortcuts e Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference Guide shows you all of the products system and assists in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want ignition coil informa tion use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the Ignition Coil section Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices A WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not strictly observed could result in dam age to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of informa tion NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation
85. malfunctioning Check Problem in the governor system Engine malfunctions at high speed Is revolution fluctuation of Plugged air hole in tank cap Clean relatively large period produced YES Entry of dust and air into fuel Clean filter or fuel pipe when a load is applied Engine malfunctions at low speed Remove spark plug and check Faulty plug insulation Replace spark by cranking engine while Fouled electrodes Clean having the plug touched against Faulty ignition coil Replace engine block Incorrect air gap Correct A WARNING Keep the plug as far away as possible from the plug hole To avoid an electric shock do not hold the plug itself Make sure to hold the plug cap Is unusual smoke emitted out of YES Overrich fuel in pilot system Turn in pilot screw by muffler NO a minor extent 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 Is air sucked through carburetor Loose flange nuts Retighten flange MG Damaged gasket Replace Are valve clearances of normal NO Compression leakage Adjust valve clearance values Wrong valve timing Correct alignment of YES timing gear marks Is alignment of timing gear NO Largely deviated valve timing Correct alignment of marks correct timing gear marks K102026B F TROUBLESHOOT
86. me reason before installing a new part clean off any dust or metal filings 2 Battery Ground Remove the ground lead from the battery before performing any disassembly operations on the equipment This prevents a the possibility of accidentally turning the engine over while partially disassembled b sparks at electrical connections which will occur when they are disconnected c damage to electrical parts 3 Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them evenly in a staggered sequence This is to avoid distortion of the part and or causing gas or oil leakage Conversely when loosening the bolts nuts or screws first loosen all of them by about a quarter of a turn and then remove them Where there is a tightening sequence indication in this Service Manual the bolts nuts or screws must be tightened in the order and method indicated Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench 5 Force Common sense should dictate how much force is necessary in assembly and 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 s
87. ments e Crankcase e Cylinder heads e Breather chamber and internal parts e Inlet pipe and tube Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts as to his ability to do the work all ad justments maintenance and repair should be carried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation To get the longest life out of your engine e Follow the Periodic Maintenance Chart in the Service Manual e alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki en gine parts Genuine parts provided as spare parts are listed in the Parts Catalog e Fo
88. minate 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 opti mum fuel economy with a suitable air cleaner and exhaust system TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED Federal law and California State law prohibits the following acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new engine for the purpose of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the engine after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Do not tamper with the original emission related part e Carburetor and internal parts e Spark plugs e Magneto or electronic ignition system e Fuel filter element e Air cleaner ele
89. mit Inlet Exhaust 11 13 mm 0 438 in KE04042BS1 C P 5 14 ENGINE TOP END Valves Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Clearance Adjustment e Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Seat Inspection e Refer to the Valve Seat Inspection in the Periodic Mainte nance chapter Valve Seat Repair e Refer to the Valve Seat Repair in the Periodic Mainte nance chapter Valve Head Thickness e Remove the valve see Valve Mechanism Removal Instal lation e Measure the valve head thickness x If the valve head thickness valve margin A is less than the service limit replace the valve with a new one A Valve Head Thickness Service Limit Inlet Exhaust 0 3 mm 0 012 in 05007881 6 Valve Stem Runout e Support the valve on V blocks at each end of the stem e Position a dial gauge perpendicular to the stem e Turn the valve and read the variation on the dial gauge x If the stem runout is greater than service limit replace the valve TIA AA Valve Stem Runout Service Limit Inlet Exhaust TIR 0 05 mm 0 002 in 6 03010751 Valve Stem Diameter e Measure the diameter of the valve stem A in two di rections at right angles at four different positions on the stem xIf any single measurement is less than the service limit
90. n stroke e Put new gaskets and the cylinder head assemblies on each cylinder NOTE OAs the head gaskets are coated with sealing agents be careful not to damage the surfaces e Tighten the cylinder head bolts following the tightening sequence as shown in the figure Torque Cylinder Head Bolts 46 N m 4 7 kgf m 34 ft lb CAUTION A torque wrench must be used to assure proper torque Improper tightening of the head bolts may result in warping of the cylinder head KE04045BS1 C e Install Rocker Arm Bracket see Valve Mechanism Removal In stallation Push Rod see Push Rod Installation Rocker Arm see Valve Mechanism Removal Installa tion e Install the new gaskets and rocker covers e Wi 2 e Tighten the rocker cover bolts following the tightening s dini quence as shown in the figure 0 i RS ll 5 Torque Rocker Cover Bolts 5 9 N m 0 60 kgf m 52 in Ib 1 V e Install the removed parts see appropriate chapters M MENI VI Push Rod Removal e Set each piston at the T D C of the compression stroke e Remove the rocker arm see Valve Mechanism Re moval Installation Pull out the push rods A NOTE OMark the push rods and rocker arms so they can be installed in their original position during assembly 5 10 ENGINE END Cylinder Head Push Rod Installation e Set each piston at the T D C of the compression stroke e Apply engine oil t
91. n air passage main air jet The resulting mixture flows out the end of the main nozzle into the carbu retor bore where it is atomized by the high speed air flow and carried into the engine The pilot system includes the pilot jet E pilot screw F idle mixture screw pilot air jet G pilot outlet H and the bypass holes I 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 itis not enough to draw fuel through the main system of the carburetor and atomize it Instead the fuel is drawn through the pilot system since the nearly closed throttle valve J 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 throt tle 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 allow ing 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
92. n hole A on the breather chamber does not accumulate with slugs e Replace the breather chamber cover gasket with a new one e Install Breather Pipe see Breather Pipe Installation Gasket Breather Chamber Cover A Clamps B e Tighten Torque Breather Chamber Cover Bolts C 5 9 N m 0 60 kgf m 52 in Ib e Install the removed parts see appropriate chapters CAMSHAFT CRANKSHAFT 7 13 Breather Breather Valve Inspection e Inspect the reed valve A for breakage crack or distor tion replace it with a new one if necessary e Inspect the plate B for damage or rough contact surface replace it with a new one if necessary e Inspect the valve seating surface The surface should be no nicks or burrs Breather Pipe Removal e Remove Breather Chamber Cover see Breather Valve Removal Breather Pipe A Breather Pipe Installation e Install the breather pipe A e Install the removed parts see appropriate chapters 7 14 CAMSHAFT CRANKSHAFT Camshaft Tappet Camshaft Tappet Removal e Set the engine on a clean surface while parts are re moved e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Crankcase Cover see Crankcase Cover Removal Cylinder Head Assembly see Cylinder Head Assembly Removal in the Engine Top End chapter e Turn the crankcase upside down so that the tappets will fall away from the cam lobes Pull the camshaft A out of t
93. n the Periodic Maintenance chapter Engine Oil Change e Refer to the Engine Oil Change in the Periodic Mainte nance chapter Oil Filter Removal e Refer to the Oil Filter Replacement in the Periodic Main tenance chapter Oil Filter Installation e Refer to the Oil Filter Replacement in the Periodic Main tenance chapter 6 8 LUBRICATION SYSTEM Pressurized Lubrication System The engine lubrication circuit is a pressurized system consisting of a positive displacement pump which picks up oil through a filter screen from the crankcase The oil is pumped to a replaceable oil filter cartridge through the engine s oil passages to lubricate internal components and return to the crankcase A pressure relief valve is used between the oil pump and oil filter to relieve excessive oil pressure by returning excess oil to the crankcase see Oil Flow Chart Oil Pressure Measurement e Remove the oil passage plug A from the crankcase e Install the oil pressure gauge adapter A and oil pressure gauge B Special Tools Oil Pressure Gauge 10 kgf cm 57001 164 Oil Pressure Gauge Adapter PT 1 8 57001 1033 e Run the engine and warm up thoroughly e Run the engine at 3 200 r min rpm and read the oil pres sure gauge xIf the oil pressure is below the specification inspect the oil pump and relief valve see OU Pump Relief Valve In spection x If the oil pump and relief valve are not at fault inspect the rest of the lubr
94. nch e Tighten the plugs Torque Spark Plugs 22 N m 2 2 kgf m 16 ft Ib e Fit the plug caps securely e Pull up the spark plug caps lightly to make sure of the installation of the spark plug caps Spark Plug Cleaning and Inspection e Refer to the Spark Plug Cleaning and Inspection in the Periodic Maintenance chapter Spark Plug Gap Inspection e Refer to the Spark Plug Gap Inspection in the Periodic Maintenance chapter TROUBLESHOOTING 10 1 Troubleshooting Table of Contents Engine Troubleshooting Guide pp 10 2 Starter Motor Troubleshooting Guide pp 10 6 10 2 TROUBLESHOOTING Engine Troubleshooting Guide If the engine malfunctions check if the way the engine is used is correct If the engine malfunc tions even if the engine is used correctly systematically carry out troubleshooting starting with simple points This chart describes typical troubleshooting procedures Do not unnecessarily disassemble the carburetor the magneto or the engine unless it has been found to be the cause of malfunctioning Engine hard to start Remove spark plug and Are sparks produced check spark by cranking when spark plug is YES gt Faulty spark plug Replace engine while having the replaced plug touched against NO engine block A WARNING AE sparks produced YES Faulty ignition coil Replace Keep the plug as far away when ignition coil is as possible from the plug replaced hole NO gt Incor
95. nd Lead C OThe side tongue D of the gasket faces 1 cylinder and PTO side as shown e Tighten KC05182BS1 C Torque Carburetor and Inlet Pipe Mounting Bolt E 5 9 N m 0 60 kgf m 52 in Ib Carburetor and Inlet Pipe Mounting Nut F 5 9 N m 0 60 kgf m 52 in Ib FR and FS Models e Replace the gasket A with a new one e Install Gasket Inlet Pipe B Ground Lead C e Tighten Torque Carburetor and Inlet Pipe Mounting Nut D 5 9 N m 0 60 kgf m 52 in Ib KC05188BS1 C FUEL SYSTEM 3 21 Carburetor e Connect the breather hose A so that the clamp knob B faces the downward e Install the removed parts see appropriate chapters FX Models C FR and FS Models D Carburetor Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the engine 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 inlet pipe see Inlet Pipe Removal e Close the fuel shut off valve in the equipment e Remove the clamp A e Disconnect Fuel Tube B Solenoid Valve Connector C FX Models D FR and FS Models E 3 22 FUEL SYSTEM Carburetor e Unhookthe throttle link spring atthe throttle shaft lever clip end B with a long nose plier e Unhook the throttle link rod C from the throttle shaft lever
96. ne is extremely flammable and can be explo sive under certain Turn the engine switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Inspect the carburetor body for damage Flange sealing surfaces should be smooth and free of burns and nicks e Turn the throttle and choke shafts to check that the throttle and choke butterfly valves move smoothly x If the valves do not move smoothly replace the carburetor body and or throttle shaft and choke shaft assembly with new ones e Check the gasket on the carburetor body x If the gasket is not in good condition replace it with a new one e Check the other parts of the carburetor for any wear or damage Replace the part with a new one if necessary e Clean and check the float level as follows CAUTION Do not push down on the float during float level checking e With the float A assembly installed onto the carburetor body hold the carburetor upside down at eye level Gen tly support the float with a finger and bring it down slowly so that the float arm tab B just touches the float valve C The float lower surface D should be parallel with the carburetor body mating surfaces E x If the float position is not correct replace the float with a new one FX Models F FR and FS Models G KC05193BS1 C KC05184BS1 C 3 30 FUEL SYSTEM Carbur
97. nhook the two retaining clamps A and remove the cap B from the air cleaner body e Remove the primary element A e Remove the secondary element A FR and FS Models e Open the air cleaner cover A e Loosen the clamp A e Remove the inlet hose B together with the element as sembly C 3 36 FUEL SYSTEM Air Cleaner e Loosen the clamp e Remove Inlet Hose B Foam Element C FS Models only Element Installation FX Models e Slide the secondary element and primary element into place in the air cleaner body e Install the cap direction as shown in the figure Upside A 41 B e Fasten the two retaining clamps C 9 KC060328W2 FR and FS Models e Install the form element A to the paper element B FS Models only 068152 Air Cleaner FUEL SYSTEM 3 37 e Install the inlet hose A and tighten the clamp B OCheck that the element C is horizontally installed e Install the inlet hose A and tighten the clamp B e Close the air cleaner cover A Element Cleaning and Inspection Air cleaner elements are not recommended to be cleaned and each air cleaner element should be replaced with new ones e Refer to the Element Cleaning and Inspection in the Pe riodic Maintenance chapter Air Cleaner Body and Bracket Removal FX Models e Remove the air cleaner elements if necessary see Ele ment Removal
98. nstalling a smaller diameter main jet in the carburetor and adjusting the idle speed NOTE OThe main jet high altitude kits are available if the equip ment is to be used in the high altitude The main jet numbers are stamped on the ends of the main jets High Altitude Main Jet Main Jet No Altitude FR FS FX L 110 0 1 000 m 0 3 000 ft 124 R 114 m L 107 1 000 2 000 m 3 000 6 122 000 ft R 111 L 104 2 000 m 6 000 ft and 120 higher R 108 KC05195BS1 C 3 18 FUEL SYSTEM Carburetor Main Jet Replacement FX Models e Close the fuel shut off valve in the equipment e Remove the carburetor see Carburetor Removal e Drain the fuel in the carburetor completely by unscrewing the drain screw at the bottom of the float chamber see Fuel System Cleanliness Inspection in the Periodic Main tenance chapter e Unscrew the chamber screws A and take off the float chamber B e Remove the float assembly A from the float chamber e Remove Pin A Float B Float Valve C Spacer D O rings E Use the rod to push the main jet L A and R B out from the bottom side of the spacer C Carburetor FUEL SYSTEM 3 19 eReplace the main jet A with a new one for altitude ex pected see High Altitude Operation e Install the new O ring B to the main jet e Using the suitable rod C press the main jet until they are bottomed to the
99. o the both ends and shaft of the push rod e Install the push rods in their original positions of the tappet hollow A e Check that both inlet and exhaust push rods on each cylinder are at lowest position on the cam lobes If the piston is not at the T D C of the compression stroke turn the flywheel clockwise one turn 360 and reset each pis ton at the T D C of the compression stroke e Be sure the end of the push rods are correctly seated on the tappets e Install the rocker arm see Valve Mechanism Removal In stallation e Check and adjust the valve clearance see Valve Clear ance Inspection in the Periodic Maintenance chapter Push Rod Inspection e Place the push rod on V blocks as far apart as possible and set a dial gauge A on the rod at a halfway point between the blocks Turn the rod to measure the runout The difference between the highest and the lowest dial readings is the amount of runout x If the runout exceeds the service limit replace the rod with a new one Rocker Arm Push Rod Runout Service Limit TIR 0 5 mm 0 02 in Valve Mechanism Removal Installation NOTE OWhen 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 Locknuts A Valve Clearance Adjusting Bolts B and Washer Collar Rocker Arm C KE04007BS1 ENGINE TOP END 5 11 Cylinder Head e Remove
100. olenoid valve connector lead C to the engine shroud clamp D as shown in the figure KH07059BS1 C FR and FS Models e Attach the stator coil lead A ignition coil lead and sole noid valve connector lead to the engine shroud with the band B FR Models C FS Models D KH07080BS1 C FX Models e Install the fan housing e Tighten Torque Fan Housing Bolts 5 9 N m 0 60 kgf m 52 in Ib e Install the screen e Tighten Torque Cooling Fan Screen Bolts 5 9 N m 0 60 kgf m 52 in Ib e Install the guard Torque Guard Mounting Bolts 5 9 N m 0 60 kgf m 52 in Ib 9 14 ELECTRICAL SYSTEM Charging System FS Models e Install the fan housing e Tighten Torque Fan Housing Bolts 8 8 0 90 kgf m 78 in Ib e Install the screen e Tighten Torque Cooling Fan Screen Bolts 5 9 N m 0 60 kgf m 52 in Ib e Install the guard e Screw the screw rivets FR Models e Install the screen e Tighten Torque Cooling Fan Screen Bolts 5 9 N m 0 60 kgf m 52 in Ib e Install the fan housing e Tighten Torque Fan Housing Bolts 8 8 N m 0 90 kgf m 78 in Ib e Install the removed parts see appropriate chapters Charging System Operational Inspection e Check the battery condition NOTE OAlways check the battery condition before judging other parts of the charging system The battery must be fully charged for accurate charging system tests e Warm up the engine to bring the com
101. on control system is used to prevent blow by gases from emitting in the air The blow by gases are led to the breather chamber through the crankcase and camshaft Then it is drawn into the clean side of the air cleaner through the cylinder head and hose and mixed with the clean air flow and subsequently comes into the combustion chamber through the carburetor and inlet 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 FX Models Fresh Air E Blow by Gas K6080338W4 C CAMSHAFT CRANKSHAFT 7 11 Breather FR and FS Models LE T A Sh A Cp be S NN a Y 3 SE ale c lt Fresh Air 22 Blow by Gas K6080348W4 C 7 12 CAMSHAFT CRANKSHAFT Breather Breather Valve Removal e Remove Stator Coil see Flywheel and Stator Coil Removal in the Electrical System chapter Unscrew the bolts A and remove the clamps B e Remove the breather chamber cover C and gasket e Remove Breather Pipe A see Breather Pipe Removal Screw B Back Plate C Reed Valve D Breather Valve Installation e Align center of the valve seat with center of the reed valve and back plate e Tighten Torque Breather Valve Mounting Screws 2 0 N m 0 20 18 in Ib Be sure the drai
102. ove it CAMSHAFT CRANKSHAFT 7 7 Crankcase Crankcase Cover Assembly e Chip the old gasket from the mating surfaces of the crankcase and cover e Using compressed air blow out the oil passage in the crankcase cover e With a high flash point solvent clean off the mating sur faces of the crankcase and the cover and wipe them dry A WARNING Clean the crankcase and cover in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean parts A fire or explosion could result e Be sure to replace the oil seal with a new one if removed OApply mineral oil to the crankshaft oil seal outside Olnstall the oil seal so that the marks A face out OThoroughly pack high temperature grease to 60 volume into the space B between the dust lip C and seal lip D Press in the new oil seal using a press or suitable tools until it is flush with flange surface E or maximum 1 mm 0 04 in F lower than the flange surface Do not damage the seal lip PTO Side G KG04089BS1 C e When replacing the oil seal A of the governor shaft note the following OApply mineral oil to the lip surface of the governor shaft oil seal Olnstall the oil seal into the crankcase cover B with a suitable tool after inserted the governor shaft C in the crankcase cover and so th
103. ponents up to their normal operating temperatures e Measure regulated output voltage at various engine speeds OConnect a voltmeter across the battery terminals The readings should show nearly battery voltage when the engine speed is low and as the engine speed rises the readings should also rise But they must stay within the specified range x If the output voltage is much higher than the specification the regulator is defective or the regulator leads are loose or open xIf the output voltage does not rise as the engine speed increase the regulator is defective or the alternator output is insufficient for the loads Regulated Output Voltage Battery Voltage to 15 V DC ELECTRICAL SYSTEM 9 15 Charging System Stator Coil Resistance e Disconnect the stator coil lead connector A e Measure the stator coil resistance Electric Starter Model OConnect an hand tester between stator pins B Special Tool Hand Tester 57001 1394 Stator Coil Resistance 0 1 0 14 Q x If the measured value is not within the specification re place the stator coil with a new one xIf the coil has normal resistance but the voltage inspec tion shows the alternator to be defective the flywheel magnets have probably weakened and the flywheel must be replaced e Check for continuity between each stator pin and ground There should be no continuity infinite ohm xIf the stator coil fails any of these tests replace the coil w
104. rcuit Test NOTE OBefore this test be sure the battery is fully charged e Disconnect the starter motor lead A from the solenoid terminal as shown and keep the lead away from the sole noid terminal 8 6 STARTER SYSTEM Electric Starter System e Measure the continuity of the solenoid when activated OSet the hand tester selector switch to the R x 1 O position and connect the leads across the large terminals A as shown in the figure OTurn the engine switch to the START II position and read the tester xIf the solenoid does not click or if the tester reads more than 0 the solenoid is faulty Replace it xIf the solenoid makes a single clicking sound the tester reads 0 and the rest of the starter circuit is good xIf solenoid clicks once but the tester does not read 0 Q the solenoid is faulty Replace it x If the solenoid does not click at all proceed with the fol lowing e Disconnect the switch lead A e Set the hand tester to the R x 1 O position and connect the leads as shown in the figure Switch Terminal A To Ground B xIf the tester does not read close to 0 the solenoid is faulty Replace it x If the tester reads close to 0 the solenoid may be good e Check the voltage to the solenoid from the engine switch e Set the hand tester selector switch to the 25 V DC position and connect it as shown in the figure Switch Lead Connector A To Ground B e Turn the engine switch to t
105. re ae epe ie cR dx eid des 7 13 Breather Pipe Installation mmm 7 13 Camshaft Tap pet EE 7 14 Camshaft Tappet Removal 7 14 Camshaft Tappet Installaton 7 14 Camshaft Disassembly ss 7 14 Camshaft Zeep 2 a doom tert Eben 7 15 1 56 EEEE E OR A A eb ERE ERG 7 15 Camshaft Bearing Journal Wear eege ENEE ient eri teta the Eege E Ee 7 15 Crankshaft Connecting Rod 7 17 Connecting Rod Rerrmou lo iue 7 17 Connecting Rod Installation ants 7 17 Crankshaft 9 7 17 Grankshaft Installation 7 17 GCleaning InspectlOr cto eiua tests et bd e bte e oe ade P Bn a a 7 17 Connecting Rod ee Tat EE 7 18 Connecting Rod Big End Crankpin Width 7 18 Connecting Rod Big End Bearing Crankpin Wear 7 19 leu curuli uU EE 7 19 Crankshaft Main Journal Wear emere 7 20 7 2 CAMSHAFT CRANKSHAFT Exploded View CAMSHAFT CRANKSHAFT 7 3 Exploded View Fastener Remarks 1 Connecting Rod Big End Cap Bolts 9 8 1 0 87 EO 2 Crankcase Cover Bolts 27 4 2 8 20 S
106. rect air gap Correct To avoid an electric shock Faulty flywheel Replace do not hold the plug itself Make sure to hold the plug cap No fuel in the tank Add eEntry of dust or air into _Clean fuel hose or filter ePlugged air hole in tank L Clean cap and fuel pump ePlugged fuel line Clean Make starting attempts a number of times and then remove spark plug and observe electrodes Are they wet Is compression sufficient Excessive use of choke Remove the plug and turn the crankshaft without loading ePlugged air cleaner Clean or replace eloo high fuel level in float Adjust bowl eWorn piston piston rings Replace eStuck piston rings Clean or replace eWorn cylinder bore Bore or replace eLoose of cylinder head Retighten bolt eFaulty contact of valve Lap seat ePlunge up by valve Adjust valve clearance eWarped cylinder head Replace eBroken valve spring Replace eStuck valve Clean or replace eBurned head gasket Replace Check carburetor eCheck for plugged fuel line eCheck for plugged air passage eCheck float level eCheck carburetor setting KIO02145B TROUBLESHOOTING 10 3 Engine Troubleshooting Guide Engine power loss Is engine overheated YES gt e Engine oil level too low Adjust level or add NO Engine oil level too high Adjust level Excessive engine load Decrease load Carburetor not properly adjusted Carbon deposit in combustion ch
107. red on the valve face The position of the valve in the seat is evident after lapping the valve x If the seat does not make proper contact lap the valve into seat with a lapper e Coat the face of valve sparingly with a fine lapping com pound e Use the lapping tool A to grip top of the valve B Rotate the valve in a circular motion to lap the valve to the seat e Lift the valve slightly from the seat every 8 to 10 strokes continue lapping operation until a uniform ring appears around entire surface of the valve face KE05006BS1 C PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures e When lapping is completed wash all parts in solvent to remove lapping compound Dry the parts thoroughly e Note the position of the lapping mark on the valve face The lapping mark should appear on or near the center of the valve face e When the engine is assembled be sure to adjust the valve clearances see Valve Clearance Adjustment Lubrication System Engine Oil Level Inspection e Place the engine on a level surface e Remove the oil filler cap A and wipe its dipstick B with a clean cloth e Insert the dipstick into tube C without screwing it in then check the oil level e The oil level should be the operating range grid area D on the dipstick xIf the oil level is ADD range E add enough engine oil to bring oil level to the operating range CAUTION Do not
108. reen Bolts 5 9 0 60 52 in lb 3 Engine Shroud Bolts FX Models 5 9 0 60 52 in lb 4 Engine Shroud Bolts FR and FS Models 8 8 0 90 78 in Ib 5 Fan Housing Bolts FX Models 5 9 0 60 52 in lb 6 Fan Housing Bolts FR and FS Models 8 8 0 90 78 in lb 7 Flywheel Bolt 56 5 7 41 8 Guard Mounting Bolts FX Models 5 9 0 60 52 in lb 9 FR Models 10 FS Models 11 FR FR without regulator mounting holes and cut out and FS Models 4 4 COOLING SYSTEM Cooling Fan Cooling Fan Removal e Referto the Flywheel and Stator Coil Removal in the Elec trical System chapter Cooling Fan Installation e Refer to the Flywheel and Stator Coil Installation in the Electrical System chapter Cooling Fan Inspection e Remove the fan housing see Flywheel and Stator Coil Removal in the Electrical System chapter e Visually inspect the blades A in the cooling fan x If they have any crack warp or damage replace the cool ing fan with a new one If any mud or dust have stuck to the cooling fan clean it e Wash the cooling fan in detergent and water CAUTION Do not clean the cooling fan in oil solvent It may be damage by oil solvent j E Kpoopm P E Engine Shroud COOLING SYSTEM 4 5 Engine Shroud Removal e Remove Spark Plug Cap see Ignition Coil Removal in the Elec trical System chapter Carburetor see Carburetor Removal Engine Shroud Bolts A Engine Shroud B FR and FS Models e Cut off the
109. rter System e Remove the insulator A e Remove the springs A e Free the brushes B from the brush holder C e Remove Brush Holder A Yoke B e Remove the armature assembly A with pinion gear fork B e Remove the front stopper A e Push the rear stopper B downward and remove the snap ring C e Pull the rear stopper and pinion clutch D from the arma ture shaft STARTER SYSTEM 8 9 Electric Starter System FR and FS Models e Remove Through Bolts A Brush Plate Assembly B e Remove York A Nut B Washer C Spring D Pinion Gear E Rubber Damper F Collar G End Cover H KLO2DOSJ Starter Motor Assembly FX Models e Apply a small amount of grease to the armature shaft A as shown in the figure e Do not reuse the snap ring B Replace it with a new one e Inspect the boots A grommet B and rubber insert C for visible damage x lf it is damaged replace the related parts 8 10 STARTER SYSTEM Electric Starter System e Install the pinion clutch A e Install the rear stopper B so that the hollow side face the outside e Install the snap ring C to the groove of the shaft e Slide the rear stopper until the stopping with the snap ring e Install the front stopper D so that the smaller diameter face the inside e Apply grease to the pinion gear fork fingers Assemble the pinion gear fork E as shown in the
110. s are warped or distorted beyond recondition ing replace the cylinder head with a new one e Pitted or worn valve seats can be refaced Lap the valves to the seats after refacing e Coat the valve seat with machinist s dye e Push the valve into the guide e Rotate the valve against the seat with a 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 OThe valve stem and guide must be in good condition or this check will not be valid Good A Too Wide B Too Narrow C Uneven D x If the valve seating pattern is not correct repair the seat Valve Seating Surface Width STD Exhaust 0 8 1 6 mm 0 039 0 059 in Inlet 1 2 1 8 mm 0 043 0 067 in Valve Seat Repair e Follow the manufacture s instructions for use of valve seat cutters Special Tools Valve Seat Cutter Holder Bar 57001 1128 Valve Seat Cutter Holder 6 57001 1360 Exhaust Valve Valve Seat Cutter 45 530 57001 1187 Valve Seat Cutter 32 533 57001 1199 Inlet Valve Valve Seat Cutter 45 535 57001 1116 Valve Seat Cutter 32 535 57001 1121 If the manufacture s instructions are not available use the following procedure KE05004BS1 KE05003BS1 PERIODIC MAINTENANCE 2 13 Periodic Maintenance Procedures Seat Cutter Operating Cares 1 This valve seat cutter is designed only for valve se
111. s generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film During assembly oil or grease whichever is more suitable should be applied to any rubbing surface which has lost its lubricative film Old grease and dirty oil should be cleaned off Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles Don t use just any oil or grease Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended This manual makes reference to molybdenum disulfide grease MoS2 in the assembly of certain engine parts Always check manufacturer recommendations before using such special lubricants 16 Electrical Wires All the electrical wires are either single color or two color and with only a few exceptions must be connected to wires of the same color On any of the two color wires there is a greater amount of one color and a lesser amount of a second color so a two color wire is identified by first the primary color and then the secondary color For example a yellow wire with thin red stripes is referred to as a yellow red wire it would be a red yellow wire if the colors were reversed to make red the main color Wire cross section Color Indicated on the Wire Color Indicated on the Wiring Diagram Yellow Red Rem 68020601 1 17 Repla
112. s the piston pin and at least 100 mm 3 94 in long and insert the arbor through the connecting rod small end OOn a surface plate set the big end arbor on V blocks OWith the connecting rod held vertically use a height gauge to measure the height difference of the small end arbor on the surface plate Using a dial gauge measure the height at two different positions and the distance of the two positions is 100 mm 3 94 in B Then deter mine the connecting rod bent from the measured height differences C x If connecting rod bend exceeds the service limit replace the connecting rod with a new one Connecting Rod Bend Service Limit TIR 0 15 100 mm 0 006 3 94 in e Measure the connecting rod twist OWith the big end arbor still on the V blocks hold the con nection rod horizontally and measure the amount that the small end arbor difference Using a dial gauge measure the height at tow different positions and the distance of the two positions is 100 mm 3 94 in A Then deter mine the connecting rod twist from the measured height differences B xlf connection rod twist exceeds the service limit replace the connecting rod with a new one Connecting Rod Twist Service Limit TIR 0 15 100 mm 0 006 3 94 in Connecting Rod Big End Crankpin Width Wear e Measure the connecting rod big end width A with a mi crometer or a dial caliper x If the measurement is less than the service limit replace the connecting rod w
113. satisfactory operation over an extended period of time any engine requires normal main tenance regular intervals The Periodic Maintenance Chart below shows periodic inspection and maintenance items and suitable intervals The bullet mark designates that the corresponding item should be performed at that interval Some adjustments require the use of special tools or other equipment An electronic tachometer will facilitate setting idle and running speeds INTERVAL OPERATION Daily First Every Every Every Every Every Every y 8 hr 25 hr 100 hr 200 hr 250 hr 300 hr 500 hr Check or clean air inlet screen 1 Check and add engine oil III l O Check for fuel and oil leakage e Check for loose or lost nuts and Screws Check battery electrolyte level e Replace air cleaner primary element Heavy Duty Air Cleaner FX Models 1 Check air cleaner secondary element Heavy Duty Air Cleaner FX Models 1 Replace air cleaner secondary element Heavy Duty Air e Cleaner FX Models 1 Clean air cleaner foam element FS Models 1 Clean air cleaner paper element FR and FS Models 1 Replace air cleaner paper element FR and FS Models 1 Clean dust and dirt from cylinder and cylinder head fins 1 Change engine oil e Clean and re gap spark plugs Check and adjust valve clearance Clean and lap valve seating surface eClean combustion chambers
114. spacer D e Assemble the carburetor see Carburetor Disassem bly Assembly FR and FS Models e Close the fuel shut off valve in the equipment e Remove the carburetor see Carburetor Removal e Unscrew the solenoid valve A and take off the float chamber B and gasket e Using a properly sized blade screw driver carefully re place the main jet A with a new one for altitude expected e Tighten Torque Main Jet 2 3 N m 0 23 kgf m 20 in Ib e Replace the float chamber gasket with a new one e Install the new gasket and float chamber e Tighten the solenoid valve Torque Solenoid Valve 4 5 N m 0 46 kgf m 40 in Ib Fuel System Cleanliness Inspection e Refer to the Fuel System Cleanliness Inspection in the Periodic Maintenance chapter KC05138BS2 C 3 20 FUEL SYSTEM Carburetor Inlet Pipe Removal FX Models e Remove Air Cleaner see Air Cleaner Body and Bracket Removal Control Panel Assembly see Control Panel Assembly Removal Inlet Pipe Mounting Bolt A and Nut B Ground Lead C Clamp D Breather Hose E Inlet Pipe F FR and FS Models e Remove Element Assembly see Element Removal Control Panel Assembly see Control Panel Assembly Removal Inlet Pipe Mounting Nut A Ground Lead B Clamp C Breather Hose D Inlet Pipe E Inlet Pipe Installation FX Models e Replace the gasket A with a new one e Install Gasket Inlet Pipe B Grou
115. t 2 3 0 23 20 in Ib Solenoid Valve 4 5 0 46 40 in Ib Throttle Valve Screws 0 68 0 069 6 0 in Ib L FR651V FR691V FS651V FS691V Models Throttle Lever Mounting Screw 0 68 0 069 6 0 in Ib L Cooling System Cooling Fan Plate Mounting Bolts Cooling Fan Screen Bolts Flywheel Bolt FX Models Engine Shroud Bolts Fan Housing Bolts Guard Mounting Bolts FR and FS Models Engine Shroud Bolts Fan Housing Bolts Engine Top End Connecting Rod Big End Cap Bolts Cylinder Head Bolts L 50 mm 2 4 PERIODIC MAINTENANCE Torque and Locking Agent Breather Chamber Cover Bolts Breather Valve Mounting Screw Starter System Fastener Remarks Cylinder Head Bolts L 60 S Rocker Arm Bracket Bolts 14 7 1 5 11 L Rocker Cover Bolts 5 9 0 60 52 mb S Spark Plugs 22 2 2 16 Valve Clearance Adjusting Locknuts 11 1 1 97 in Ib Lubrication System Engine Oil Drain Plug 6 9 0 70 61 in Ib Oil Pump Cover Plate Bolts 5 9 0 60 52 in lb FX Models Oil Filler Mounting Bolt 5 9 0 60 52 mb FR and FS Models Oil Filler Mounting Bolt 8 8 0 90 78 in lb Camshaft Crankshaft Connecting Rod Big End Cap Bolts EO Crankcase Cover Bolts S Crankcase Cover Oil Passage Plugs L Crankcase Oil Passage Plugs L Starter Motor Mounting Bolts 19 6 2 0 14 FR and FS Models Starter Motor Through Bolts 3 95 0 40 35 in Ib Electrical System Flywheel Bolt 56 5 7 41 Ignition Coil Bolts 5 9 0 60 52 Spark Plugs 22 2 2 16 Stator Coil Screws 3 4 0 35
116. them FX Models B FR and FS Models C Brush Length Standard FX Models 10 0 mm 0 39 in FR and FS Models Service Limit FX Models 6 0 mm 0 24 in FR and FS Models 10 16 mm 0 4 in Brush Spring Inspection e Inspection the brush springs for pitting cracks rusting and burrs Replace the spring if necessary Inspect the springs for weakened conditions and distor tion Replace the spring if necessary xIf the brush springs are able to press the brushes firmly into place they may be considered serviceable If they cannot replace them STARTER SYSTEM 8 13 Electric Starter System Armature Inspection e Inspect the surface of the commutator A x lf it is scratched or dirty polish it with a piece of very fine emery cloth B and clean out the grooves GP11061081 C e Measure the depth of the grooves between the commu tator segments xIf the grooves are shallower than the specified limit re place the armature with a new one x If the grooves are only dirty clean them carefully Commutator Groove Depth Standard FX Models 0 6 mm 0 02 in and FS Models Service Limit KHO9013BS1 FX Models 0 2 mm 0 008 in FR and FS Models 1 27 mm 0 05 in Bad A Segment B Good C 0 2 mm 0 008 in FX Models 1 27 mm 0 05 in FR and FS Models limit D Mica E e Measure the outside diameter A of the commutator B at several points x If the diam
117. udes any appliance with a pilot light FX Models e Place a suitable container A under the drain screw B on the carburetor e Turn out the drain screw a few turns to drain the carbu retor and check if water or dirt has accumulated in the carburetor Tighten the drain screw FR and FS Models e Place a suitable container under the carburetor e Remove Solenoid Valve Connector A Solenoid Valve B Float Chamber C and Gasket e Check if water or dirt has accumulated in the carburetor e Install the removed parts see appropriate chapters xIf any water or dirt is found clean the carburetor see Carburetor Cleaning in the Fuel System chapter and fuel tank And check the fuel filter see Fuel Filter Inspection in the Fuel System chapter Periodic Maintenance Procedures PERIODIC MAINTENANCE 2 9 Element Cleaning and Inspection Air cleaner elements are not recommended to be cleaned and each air cleaner element should be replaced with new ones at the maintenance time as shown in the maintenance chart NOTE OOperating in dusty condition may require more frequent maintenance than above FX Models e Remove the elements see Element Removal in the Fuel System chapter e Replace the primary element A every 250 hrs e Replace the secondary element A with a new one if dirty when primary element is checked e Replace the secondary element every 500 hrs CAUTION Do not wash air cl
118. uel Pump Inspection e Check the vent holes A and filter B for plugging or clog ging x If vent hole and filter are plugged or clogged remove the foreign material from them 3 34 FUEL SYSTEM Fuel Pump Fuel Filter Fuel Flow Test A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the engine switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Disconnect the fuel pump outlet nozzle from the tube e Connect a suitable hose A to the outlet nozzle e Run the lower end of the hose into a container e Start the engine check the fuel flow x If fuel flow is none or little replace the fuel pump with a new one Check for clogged or damaged tubes and fuel filter Re place the faulty parts Fuel Filter Removal Installation e Remove Clamp A Fuel Filter B e When install the fuel filter arrow mark C faces fuel pump side Fuel Filter Inspection e Visually inspect the fuel filter A x If the filter is clear with no signs of dirt or other contami nation replacement of the fuel filter is not necessary x If the filter is dark or looks dirty replace it with a new one Also check the rest of the fuel system for contamination qe Kom P KCOTBOIO P FUEL SYSTEM 3 35 Air Cleaner Element Removal FX Models e U
119. umber of important precautions that you must follow when servicing electrical systems Learn and observe all the rules below ODo not reverse the battery cable connections This will burn out the diodes in the electrical parts OAlways check the battery condition before judging other parts of the electrical system A fully charged battery is necessary for conducting accurate electrical system tests not hit the electric parts with a hammer or do not drop the electric parts These may result in the electric parts damage or breakage OTo prevent damage to electrical parts do not disconnect the battery cables or any other electrical connections when the engine switch is on or while the engine is running OBecause of the large amount of current never keep the engine switch turned to the start position when the starter motor will not start or the current may burn out the starter motor windings OTake care not to short the leads that are directly con nected to the battery positive terminal to the chassis ground OTroubles may involve one or all items in some cases Never replace a defective part without determining what CAUSED the failure If the failure was occurred by an other item or some other items repair and or replace the item s Or the failure may happen again OMake sure all connectors in the circuit are clean and tight and examine the leads for signs of burning fraying etc Poor leads and bad connections will affe
120. urn on the growler and rotate the armature one complete turn xlf the metal strip vibrates the windings are internally shorted to each other and the starter motor must be replaced KH08014BS1 0 028079 090158 5 Electric Starter System STARTER SYSTEM 8 15 Yoke Assembly Inspection e Setthe multimeter selector switch to the R x 1 kO position and measure the resistance between the positive brushes and stator motor yoke x If the resistance is less than infinite the positive brush is shorted to ground Replace the yoke assembly FX Models A FR and FS Models B Positive Brush to Ground Resistance e Set the multimeter selector switch to the R x 1 O posi tion and measure the resistance between the negative brushes and starter motor yoke x If the meter dose not read close 0 the yoke assembly is faulty Replace it FX Models A FR and FS Models B Negative Brush to Ground Resistance Close 00 Pinion Clutch Inspection FX Models e Remove the pinion clutch e Turn the pinion gear A by hand The pinion gear should turn counterclockwise freely but should not turn clock wise xIf the pinion clutch dose not operate as it should or if it makes noise replace the pinion clutch ELECTRICAL SYSTEM 9 1 Electrical System Table of Contents WE 9 2 eene de EE 9 4 Special EE 9 5 Wiring AGIAN EE 9 6
121. ve the flywheel B CAUTION Always use flywheel puller e Free the stator coil lead from the clamp e Remove Woodruff Key A Stator Coil Screws B Stator Coil C 9 12 ELECTRICAL SYSTEM Charging System FR and FS Models e Cut off the band FR Models B FS Models C Flywheel and Stator Coil Installation e Install the stator coil and hold the stator coil lead to the clamp e Tighten Torque Stator Coil Screws 3 4 N m 0 35 kgf m 30 in Ib e Using a cleaning fluid clean off any oil or dirt on the fol lowing portions and dry them with a clean cloth Crankshaft Tapered Portion A Flywheel Tapered Portion B e Fit the woodruff key C securely in the slot in the crank shaft before installing the flywheel e Install the flywheel onto the crankshaft taper so that the woodruff key fits in the key way in the hub of the flywheel e Install the bracket A and washer B e Tighten Torque Flywheel Bolt C 56 N m 5 7 kgf m 41 ft Ib e Install the ignition coils see Ignition Coil Installation KH07081BS1 C KH07055BS1 C ELECTRICAL SYSTEM 9 13 Charging System e Install the cooling fan A e Install the plate B so that the slits C fit to the bosses D on the fan e Tighten Torque Cooling Fan Plate Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib FX Models e Attach the stator coil lead A ignition coil lead B and s
122. with new ones Install bearings with the manufacturer and size marks facing out applying pressure evenly with a suitable driver to the end of the race that contacts the press fit portion and press it evenly over the base component 4 x 7 GENERAL INFORMATION 1 3 Before Servicing 12 Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally dam ages seals When pressing in a seal which has manufacturer s marks press it in with the marks facing out Seals should be pressed into place using a suitable driver which contacts evenly with the side of seal until the face of the seal is even with the end of the hole 13 Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips Before a shaft passes through a seal apply a little oil preferably high temperature grease on the lips to reduce rubber to metal friction 14 Circlip Retaining Ring and Cotter Pin When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more Install the circlip with its chamfered side facing load side as well Replace any circlips retaining rings and cotter pins that were removed with new ones as re moval weakens and deforms them If old ones are reused they could become detached while running leading to a problem 15 Lubrication Engine wear i
123. xIf warp exceeds the service limit repair the head by lap ping the mating surface with emery paper secured to a surface plate first No 200 than No 400 If the mating surface is badly damaged replace the cylinder head Cylinder Head Warp Service Limit 0 05 mm 0 002 in e Check the cylinder head for cracks or other damage e Cracks not visible to the eye may be detected by coating the suspected area with mixture of 2596 kerosene and 75 light engine oil e Wipe the area dry and immediately apply a coating of zinc oxide dissolved in wood alcohol If a cracks is present the coating will become discolored at the defective area e If a cracks is present in the cylinder head replace it e Inspect the mating surface for burrs and nicks Rocker Arm Inspection e Measure the diameter A of the rocker shafts with a mi crometer at several points of bearing the rocker arm x If the outside diameter is less than the service limit re place the rocker shaft Rocker Shafts Outside Diameter Service Limit Inlet Exhaust 10 91 mm 0 430 in e Clean and inspect the rocker arm where it touches the push rod and valve stem x If the contact points A are worn or damaged replace the rocker arm e Measure the inside diameter B of the rocker arm at sev eral points using a dial bore gauge or inside micrometer lf the inside diameter is more than the service limit re place the rocker arm Rocker Arm Inside Diameter Service Li
124. y Ng WLS P lt NS NSSSSSSSNSNN p E sssSSSS SS KF040148W5 C LUBRICATION SYSTEM 6 5 Specifications Standard Engine Oil Grade SF SG SH SJ or SL class Viscosity SAE40 SAE30 SAE10W 30 SAE10W 40 or SAESW 20 Capacity When the oil filter is not 1 8 L 1 9 US qt removed When the oil filter is removed 2 1 2 2 US qt Level Operating range grid area ADD and FULL on dipstick Oil Pressure 294 to 588 kPa 43 to 85 psi Engine oil temperature 50 C to 60 122 144 F 93 200 r min rpm qoe Oil Pump Inner and Outer Rotor Clearance 0 2 mm 0 008 in Outer Rotor Outside Diameter 52 31 mm 2 059 in Outer Rotor Thickness 14 91 mm 0 5870 in Pump Housing Inside Diameter 52 721 mm 2 0756 in Pump Housing Depth 15 16 mm 0 5968 in Relief Valve Spring Free Length 20 4 mm 0 803 in 6 6 LUBRICATION SYSTEM Special Tools Oil Pressure Gauge 10 kgf cm 57001 164 7570164ST C Oil Pressure Gauge Adapter PT 1 8 57001 1033 7571033ST C Engine Oil and Oil Filter LUBRICATION SYSTEM 6 7 CAUTION Engine operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure and accident Engine Oil Level Inspection e Refer to the Engine Oil Level Inspection i

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