4-stroke air-cooled gasoline engine
Quick Reference Guide This quick reference guide will assist you in locating a desired topic or procedure. Bend the pages back to match the black tab of the desired chapter number 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 specific topic required.
FJ180V 4-stroke air-cooled gasoline engine All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
LIST OF ABBREVIATIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) ATDC after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center psi pound(s) per square inch degree(s) Celsius r revolution DC direct current rpm revolution(s) per minute F farad(s) TDC top dead center degree(s) Fahrenheit TIR total indicator reading ft foot, f
EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems (EM) in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. 1. Crankcase Emission Control System A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow-by gases are led to the breather chamber through the crankcase.
Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.
GENERAL INFORMATION 1-1 General Information 1 TABLE OF CONTENTS Before Servicing ........................................................................................................................ Model Identification.................................................................................................................... General Specifications............................................................................................................... Torque and Locking Agent............
1-2 GENERAL INFORMATION Before Servicing Before starting to service the engine, carefully read the applicable section to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is required for successful work. Especially note the following: (1) Dirt Before removal and disassembly, clean the engine.
GENERAL INFORMATION 1-3 Before Servicing 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.
1-4 GENERAL INFORMATION Model Identification
GENERAL INFORMATION 1-5 General Specifications Items FJ180V Type of engine Forced air-cooled, vertical shaft, OHV, 4-stroke gasoline engine Bore x Stroke 65 mm x 54 mm (2.56 in x 2.13 in) Piston displacement 179 mL (10.9 cu. in) Direction of rotation Counterclockwise facing the PTO shaft Compression release Automatic compression release High idle speed 3200 rpm Ignition system Flywheel magneto with CDI RFI Per Canada and U.S.A.
1-6 GENERAL INFORMATION Torque and Locking Agent The following tables list the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or liquid gasket. Letters used in the "Remarks" column mean: L : Apply a non-permanent locking agent to the threads. M : Apply a molybdenum disulfide lubricant (grease or oil) to the threads, seated surface, or washer. O : Apply an oil to the threads, seated surface, or washer.
GENERAL INFORMATION 1-7 Torque and Locking Agent The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads. Basic Torque for General Fasteners Threads dia (mm) 4 5 6 8 Torque N·m 2.0 3.4 5.9 15 kgf·m 0.20 0.35 0.60 1.
PERIODIC MAINTENANCE 2-1 Periodic Maintenance 2 TABLE OF CONTENTS Periodic Maintenance Chart ...................................................................................................... Specifications ............................................................................................................................ Special Tools ............................................................................................................................. Periodic Maintenance Procedures...
2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart To ensure satisfactory operation over an extended period of time, any engine requires normal maintenance regular intervals. The Periodic Maintenance Chart below shows periodic inspection and maintenance items and suitable intervals. The bullet mark ( ) designates that the corresponding item should be performed at that interval. Some adjustments require the use of special tools or other equipment.
PERIODIC MAINTENANCE 2-3 Specifications Item Fuel System High idle speed Air cleaner: Type Pre-cleaner Second-stage cleaner Engine Top End Valve clearance Valve seating surface angle Valve seating surface width Lubrication System Engine oil: Type Viscosity Capacity Level Electrical System Spark plug gap Standard 3200 r/min (rpm) Dual stage filtration system Foam element Paper element Intake Exhaust 0.10 ~ 0.15 mm (0.004 ~ 0.006 in.) Intake Exhaust 45 Intake Exhaust 0.6 ~ 0.9 mm (0.024 ~ 0.035 in.
2-4 PERIODIC MAINTENANCE Special Tools Valve Seat Cutter, 45 - f27.5: 57001–1114 Valve Seat Cutter Holder Bar: 57001–1128 Valve Seat Cutter, 32 - f25.0: 57001–1118 Valve Seat Cutter Holder - f6.0: 57001–1360 Valve Seat Cutter, 32 - f28.
PERIODIC MAINTENANCE 2-5 Periodic Maintenance Procedures Fuel System High Idle Speed Adjustment CAUTION Do not adjust high idle speed with the air cleaner removed. • Start and warm up the engine throughly. WARNING Always keep your hands clear of the moving parts. the throttle lever at a dash to the high idle position. • Move Loosen control panel mounting bolts [A] enough to • move thethecontrol panel assembly. Carefully move the panel assembly right or left to • obtain the specifiedcontrol high idle speed.
2-6 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel Filter Inspection insect the fuel filter [A]. • Visually If the filter is clear with no signs of dirt or other contami- • nation, it is OK and need not be replaced. If the filter is dark or looks dirty, replace with a new one. Also check the rest of the fuel system for contamination. Check the O-ring at the tank drain for damage. Replace the O-ring with a new one if it is damaged. Air Element Removal • Move the holders [A].
PERIODIC MAINTENANCE 2-7 Periodic Maintenance Procedures Air Element Installation • Install: Foam Element • Paper Element Install the hollow [A] of the air cleaner case and projection [B] of the air cleaner body are fitting. • Move the holders [A]. Air Element Cleaning and Inspection NOTE In dusty areas, the elements should be cleaned more frequently than the recommended intervals.
2-8 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Cleaner Housing (Case and Body) Inspection the housing with detergent and water and dry thor• Clean oughly. the housing for deformation or other damage. The • Check housing must seal well and permit only filtered air to reach • the carburetor. If the housing is damaged, it must be replaced. Check that no foreign material is obstructing the air passage.
PERIODIC MAINTENANCE 2-9 Periodic Maintenance Procedures check the valve clearance. • Then Using a thickness gauge [A], measure the valve clearance beween the rocker arm [B] and the valve stem end. If the valve clearance is incorrect, adjust it. Valve Clearance (when cold) Intake, Exhaust 0.10 ~ 0.15 mm (0.004 ~ 0.006in.) Valve Clearance Adjustment valve repairs change the valve clearance, adjust • Since the valve clearance to the specification.
2-10 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE The 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] If the valve seating pattern is not correct, repair the seat. Valve Seating Surface Width (STD) Inlet, Exhaust 0.6 ~ 0.9 mm (0.024 ~ 0.035 in.) Valve Seat Repair the manufacturer’s instructions for use of valve • Follow seat cutters. Special Tools Intake Valve: Seat Cutter 45 - f27.5 Outside Cutter 32 - f28.
PERIODIC MAINTENANCE 2-11 Periodic Maintenance Procedures Marks Stamped on the Cutter: The marks stamped on the back of the cutter represent the following. 1 Cutter number, selected from 1 to 12 30 37.5 Cutter angle [A] Cutter diameter of cutter [B] KS8B Manufactured lot number Operating Procedures: Clean the seat area carefully. Recondition the valve seats with the valve seat cutters (45 , 32 ) and lap the valves. Check the seats for good contact all the way around with machinist’s dye.
2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures a 32 seat cutter [A] to narrow the seat width to the • Use STD width. Turn 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 Keep the seat width as close as possible to the STD width. Make a light pass with the 45 cutter to remove any pos• sible burrs at the edge of the seat.
PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Lubrication System Oil Level Inspection the engine on a level surface. • Place Remove the oil filler cap [A] and wipe its dipstick [B] with • a clean cloth. the dipstick into gauge hole [C] without screwing it • Insert in, then check the oil Level. oil level should be the operating range [A] (grid area) • The on the dipstick. If the oil level is below “ADD” range [B], add enough engine oil to bring oil level to the operating range.
2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures the oil filler cap and pour in the specified type • Remove and amount of oil. Engine Oil : Type: Viscosity: Capacity: SF, SG, SH or SJ Class SAE30, SAE10W-30 [When engine is completely dry] 0.65 L (0.69 US-qt) Electrical System Spark Plug Cleaning and Inspection the spark plug (See Electrical System chapter).
FUEL SYSTEM 3-1 Fuel System TABLE OF CONTENTS Exploded View........................................................................................................................... Specifications ............................................................................................................................ Governor Link Mechanism......................................................................................................... Control Panel Assembly Removal ............................
3-2 FUEL SYSTEM Exploded View
FUEL SYSTEM 3-3 Exploded View Torque No. 1 2 3 Fastener Govenor Arm Clamp Nut Fuel Tank Cover Bolts Tank Drain Bolt N·m 7.8 6.9 6.9 kgf·m 0.80 0.70 0.
3-4 FUEL SYSTEM Exploded View
FUEL SYSTEM 3-5 Exploded View Torque No. 1 2 3 4 5 Fastener Priming Nut Throttle Valve Screw Main Jet Float Chamber Mounting Bolt Drain Screw N·m 1.2 0.7 1.1 5.4 4.2 kgf·m 0.12 0.07 0.11 0.55 0.43 ft·lb 11 in·lb 6 in·lb 9.
3-6 FUEL SYSTEM Specifications Standard Item FJ180V Caburetor Specification: Make/ type Walbro LMJ-17A Throttle bore diameter 20 mm (0.79 in.) Venturi diameter 14 mm (0.55 in.
FUEL SYSTEM 3-7 Governor Link Mechanism Control Panel Assembly Removal • Remove: Air Cleaner (see Cleaner Body Removal) Recoil Starter (see Electrical System chapter) Fuel Tank (see Fuel Tank Removal) Control Panel Mounting Bolts [A] the control panel [B] unhooking the governor • Remove spring [A] end loop at the panel bracket. Control Panel Assembly Installation • • • • If any part is worn or damaged, replace the control panel. Install the control panel. Tighten the control panel mounting bolts.
3-8 FUEL SYSTEM Governor Link Mechanism Governor Arm Installation the governor arm [A] onto the governor shaft [B] • Install temporarily. sure the link spring [C] around the throttle link rod [D] • Be is in place and that it pulls the governor arm and throttle • • • • lever [E] toward each other. Loosen the clamp nut [F] on the governor arm enough to move the governor shaft. Turn the top end of the governor arm counterclockwise [G] to fully open the carburetor throttle valve and hold it there.
FUEL SYSTEM 3-9 Governor Link Mechanism Governor Assembly Installation • Instal the sleeve [A] on the governor assembly [B]. CAUTION First install the sleeve. The sleeve cannot be installed after the governor gear assembly has been installed. install, first place the thrust washer [C] on the boss of • To the shaft [D]. Then, install the governor assembly (with • the sleeve attached) on the shaft so that step [E] is fitted securely in groove [F].
3-10 FUEL SYSTEM Carburetor Fuel and Air Flow 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 during moderate to high load conditions. Fuel flows through the main jet and into the main nozzle, where it is joined by air from the main air passage (main air jet).
FUEL SYSTEM 3-11 Carburetor High Idle Speed Adjustment Refer to High Idle Speed Adjustment in the Periodic Maintenance Chapter (2nd chapter). High Altitude Operation At high altitude, the standard carburetor air-fuel mixture will be excessively rich. Performance will decrease, and fuel consumption will increase. High altitude performance can be improved by installing a smaller diameter main jet in the carburetor and correct high idle speed.
3-12 FUEL SYSTEM Carburetor the primer pipe [A] and drain screw as shown. • Install 90 ~ 100 [B] Fuel System Cleanliness Inspection Refer to Fuel System Cleanliness Inspection in the Periodic Maintenance Chapter (2nd chapter). Carburetor Removal WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the engine switch stop position. Do not smoke.
FUEL SYSTEM 3-13 Carburetor Carburetor Disassembly/Assembly to the illustration shown for disassembly and as• Refer sembly. are several passage plugs (Ball plugs) in the car• There buretor body. Do not remove. disassembly, mark the out side of throttle valve for • Before assembling them. the pilot screw in accordance with the following • Replace procedure if necessary.
3-14 FUEL SYSTEM Carburetor Carburetor Cleaning WARNING Clean the carburetor in a well-ventilated area, and take care that there is no sparks or flame anywhere near the working area, this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low flash -point solvents to clean the carburetor. CAUTION Do not use compressed air on an assembled carburetor, or the float may be crushed by the pressure.
FUEL SYSTEM 3-15 Carburetor Carburetor Inspection WARNING Gasoline is extremely flammable and can be explosive under certain. Turn the engine switch stop position. 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. the carburetor body for damage. Flange sealing • Inspect surfaces should be smooth and free of burrs and nicks. • • • • Replace the gasket if necessary.
3-16 FUEL SYSTEM Priming Pump Priming Pump Removal the tube [A] from the priming pump. • Remove Remove the nut [B] and washer [C]. • Remove the priming pump from the intake manifold. • Inspect the priming pump for damages. • If a damage is present in the priming pump, replace it. Priming Pump Installation the priming pump in the intake manifold. • Install Install the washer [A] and tighten the nut [B]. • Torque - Priming Nut: 1.2 N·m (0.12 kgf·m, 11 in·lb) • Install the tube [C] on the priming pump.
FUEL SYSTEM 3-17 Intake Manifold Intake Manifold Removal the intake manifold mounting bolts [A]. • Unscrew Remove the breather pipe [B] from the intake manifold. • Intake Manifold Installation the O-ring [A] with a new one. • Replace Clean the • manifold. mating surface of the carburetor and intake the mating surface of the carburetor and intake • Clean manifold and install the new gasket [A] and intake manifold. the spacers [A] and tighten the intake manifold • Install mounting bolts [B].
3-18 FUEL SYSTEM Fuel Tank Fuel Tank Removal • Remove: Air Cleaner (see Cleaner Body Removal) Recoil Starter (see Electrical System chapter) Oil Gauge Fuel Tank Cover Bolts [A]. a suitable container beneath the fuel hose. • Place Loosen • buretor. the clamp and remove the fuel hose from the carthe clamp and remove the fuel hose from the tank • Loosen drain. the fuel tank. • Remove Remove the tank drain from the fuel tank. • Fuel Tank Installation the tank drain [A] in the fuel tank as shown.
FUEL SYSTEM 3-19 Fuel Tank Fuel Tank Cleaning WARNING Clean the fuel tank in a well-ventilated area, and take care that there is no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low flash-point solvent to clean the tank. the fuel tank (see Fuel Tank Removal). • Remove the solvent out of the tank. • Pour Pour some high flash-point solvent into the fuel tank and • shake the tank to remove dirt and fuel deposits.
3-20 FUEL SYSTEM Fuel Filter Fuel Filter Inspection Refer to Fuel Filter Inspection in the Periodic Maintenance Chapter (2nd chapter).
FUEL SYSTEM 3-21 Air Cleaner Element Removal Refer to Air Element Removal in the Periodic Maintenance Chapter (2nd chapter). Element Installation Refer to Air Element Instalation in the Periodic Maintenance Chapter (2nd chapter). Element Cleaning and Inspection Refer to Air Element Cleaning and Inspection in the Periodic Maintenance Chapter (2nd chapter). Cleaner Body Removal • Move the holders [A]. up the latches [A] and remove the air cleaner case • Push [B].
3-22 FUEL SYSTEM Air Cleaner • Move the holders [A]. Housing (Case and Body) Inspection Refer to Air Cleaner Housing (Case and Body) Inspection in the Periodic Maintenance Chapter (2nd chapter).
COOLING SYSTEM 4-1 Cooling System TABLE OF CONTENTS Exploded View........................................................................................................................... Cooling Fan ............................................................................................................................... Cooling Fan Removal .......................................................................................................... Cooling Fan Installation ..............................
4-2 COOLING SYSTEM Exploded View
COOLING SYSTEM 4-3 Exploded View Torque No. 1 2 Fastener Flywheel Bolt Fuel Tank Cover Bolts N·m 42 6.9 kgf·m 4.3 0.
4-4 COOLING SYSTEM Cooling Fan Cooling Fan Removal Refer to Flywheel Removal in Electrical System Chapter. Cooling Fan Installation Refer to Flywheel Installation in Electrical System Chapter. Cooling Fan Inspection inspect the blades [A] in the cooling fan [B]. • Visually If they are any cracks, warps or damage, replace the cool- • ing fan. If any mud or dust have stuck to the cooling fan, clean it. Cooling fan is cleaned by washing in detergent and water.
ENGINE TOP END 5-1 Engine Top End TABLE OF CONTENTS Exploded View........................................................................................................................... Specifications ............................................................................................................................ Special Tools ............................................................................................................................. Cylinder Head.............................
5-2 ENGINE TOP END Exploded View
ENGINE TOP END 5-3 Exploded View Torque No. 1 2 3 4 5 6 7 Fastener Cylinder Head Bolts Valve Clearance Lock Screws Connecting Rod Big End Cap Bolts Rocker Arm Bolts Spark Plug Rocker Cover Mounting Bolts Muffler Cover Self Tap Bolt (1) O: Apply engine oil. S: Follow the specific tightening sequence. N·m 22 6.9 5.9 28 22 5.9 6.9 kgf·m 2.2 0.70 0.60 2.8 2.2 0.60 0.
5-4 ENGINE TOP END Specifications Item Service Limit Cylinder Head: Cylinder compression (MIN) Cylinder head warp Valves: Valve head thickness [196 kPa (28.4 psi)] (MIN) 0.03 mm (0.001 in.
ENGINE TOP END 5-5 Special Tools Compression Gauge: 57001–221 Piston Ring Compression: 57001–1095 Piston Ring Compression Belt, f55 ~ f67: 57001–1096 Compression Gauge Adapter M14 ×1.
5-6 ENGINE TOP END Cylinder Head Compression Measurement measuring compression, do the following. • Before Thoroughly warm up the engine so that engine oil be- • • tween the piston and cylinder wall will help seal compression as it does during normal running. Stop the engine. Disconnect the spark plug cap of and remove the spark plug. Attach the compression gauge assembly firmly into spark plug hole.
ENGINE TOP END 5-7 Cylinder Head Cylinder Head Assembly Removal • Remove: Air Cleaner (see Fuel System chapter) • • Recoil Starter (see Electrical System chapter) Fuel Tank (see Fuel System chapter) Muffler (see Muffler Removal) Fan Housing (see Flywheel Removal) Intake Manifold and Carburetor (see Fuel System chapter) Spark Plug Loosen the rocker cover mounting bolts [A] and remove the cover [B] and gasket. When removing the cylinder head, set at T.D.C of Power stroke in.
5-8 ENGINE TOP END Cylinder Head Push Rod Removal at T.D.C of power stroke in. • Set Remove • Removal).the rocker cover (see Cylinder Head Assembly the valve clearance adjusting nuts [A]. • Loosen Move the • ends. rocker arms [B] to clear the push rod upper • Pull out the push rods. NOTE Mark the push rods so they can be installed in their original positions during assembly. Push Rod Installation at T.D.C of power stroke in. • Set Install • der.
ENGINE TOP END 5-9 Cylinder Head Valve Mechanism Removal/Installation the cylinder head assembly (see Cylinder Head • Remove Assembly Removal). NOTE When removing the valve mechanism parts, note their position so that they may be reinstalled in their original position during assembly. • Remove: Valve Clearance Adjusting Nuts [A] Rocker Arms [B] the valve head in the combustion chamber with • Support a suitable block.
5-10 ENGINE TOP END Cylinder Head Rocker Arm Inspection and inspect the rocker arm where it touches the • Clean push rod and valve stem. If the contact points [A] are worn or damaged, replace the rocker arm.
ENGINE TOP END 5-11 Valves Valve Clearance Inspection Refer to Valve Clearance Inspection in the Periodic Maintenance Chapter (2nd chapter). Valve Clearance Adjustment Refer to Valve Clearance Adjustment in the Periodic Maintenance Chapter (2nd chapter). Valve Seat Inspection Refer to Valve Seat Inspection in the Periodic Maintenance Chapter (2nd chapter). Valve Seat Repair Refer to Valve Seat Repair in the Periodic Maintenance Chapter (2nd chapter).
5-12 ENGINE TOP END Valves Valve Guide Inside Diameter a small bore gauge or a micrometer to measure the • Use inside diameter [A] of the valve guides [B] at three places down the length of the guides. If the measurement is more than the service limit, replace the cylinder head with a new one. Valve Guide Inside Diameter Service Limit (IN, EX) : 6.08 mm (0.239 in.) Valve Spring Inspection the valve spring for pitting, cracks, rusting, and • Inspect burns. Replace the spring if necessary.
ENGINE TOP END 5-13 Cylinder, Piston Piston Removal • Remove: Air Cleaner (see Fuel System chapter) Recoil Starter (see Electrical System chapter) Fuel Tank (see Fuel System chapter) Flywheel (see Electrical System chapter) the crankcase cover (see Camshaft/Crankshaft • Remove chapter). the camshaft (see Camshaft/Crankshaft chap• Remove ter). the crankshaft to expose the connecting rod cap • Turn bolts [A]. • Remove the bolts and take off the connecting rod cap [B].
5-14 ENGINE TOP END Cylinder, Piston spread the ring opening with your thumbs and • Carefully then push up on the opposite side of the ring [A] to remove • it. Remove the 3-piece oil ring with your thumbs in the same manner. Piston Installation the expander [A] in the piston oil ring groove so that • Install the expander ends [B] touch together, never overlap. the upper and lower steel rails. There is no UP or • Install Down to the rails. They can be installed either way.
ENGINE TOP END 5-15 Cylinder, Piston engine oil to the piston pin. • Apply Assemble the piston onto the connecting rod as follows: • Set the arrow mark [A] on the piston head come reverse side of the “K” mark [B] side the connecting rod, then insert the piston pin into the piston pin hole. • Install the snap ring [A] in the piston [B] as shown. CAUTION Do not reuse the snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall.
5-16 ENGINE TOP END Cylinder, Piston CAUTION The connecting rod and the connecting rod big end cap are machined at the factory in the assembled state, so they must be replaced together as a set. engine oil to the inner surface [A] of the connecting • Apply rod big end [B] and cap [C]. rod and cap aligning the mark [D] of rod to the mark of • Set cap, install the connecting rod big end cap in their original • • position on connecting rod big end. Apply a small amount of engine oil to the cap bolts [E].
ENGINE TOP END 5-17 Cylinder, Piston Piston Ring and Ring Groove Wear the piston (see Piston Cleaning). • Clean Visually inspect the piston rings and ring grooves. • If the piston rings are worn unevenly or damaged, replace • them. If the ring grooves are worn unevenly or damaged, replace both the piston and piston rings. Measure the clearance between the top and second rings and their grooves using a thickness gauge [A].
5-18 ENGINE TOP END Cylinder, Piston Piston Pin, Piston Pin Hole, and Connecting Rod Wear the piston pin. • Remove Measure diameter of the piston pin with a micrometer • at severalthepoints. If the outside diameter is less than service limit, replace the piston pin. Piston Pin Outside Diameter Service Limit: 15.96 mm (0.628 in.) the inside diameter [A] of the piston pin hole at • Measure several points on both side. Use a dial bore gauge.
ENGINE TOP END 5-19 Cylinder, Piston Cylinder Inside Diameter and measure the cylinder inside diameter. • Clean Use a dial bore gauge to measure front-to-back and side -to-side at the points shown figure. If any of the cylinder bore measurements is greater than the service limit, replace the cylinder with a new one. 10 mm (0.39 in.) [A] Middle [B] Cylinder Inside Diameter Standard: 64.98 ~ 65.00 mm (2.558 ~ 2.559 in.) Service Limit: 65.10 mm (2.563 in.) Cylinder Bore Out-of-Round Standard: 0.01 mm (0.
5-20 ENGINE TOP END Muffler Muffler Removal • Remove: Muffler Cover Self Tap Bolt [C] • • Muffler Cover Nuts [A] Muffler Cover [B] Muffler Remove the gasket. Do not use unnecessary force on the muffler when removing the muffler assembly, or they could become damaged or distored. Muffler Installation the gasket surface and install a new gasket each • Clean time the muffler installed. the muffler. • Install Install the cover. • Tighten themuffler muffler cover nuts and self tap bolt.
LUBRICATION SYSTEM 6-1 Lubrication System TABLE OF CONTENTS Exploded View........................................................................................................................... Engine Oil Flow Chart................................................................................................................ Specifications ............................................................................................................................ Engine Oil .............................
6-2 LUBRICATION SYSTEM Exploded View
LUBRICATION SYSTEM 6-3 Exploded View Torque No. 1 2 3 Fastener Oil Drain Plug Tank Drain Bolt Oil Filter Cover Bolt O: Apply engine oil. N·m 22 6.9 6.9 kgf·m 2.2 0.70 0.
6-4 LUBRICATION SYSTEM Engine Oil Flow Chart
LUBRICATION SYSTEM 6-5 Specifications Item Standard Engine Oil: Type SF, SG, SH or SJ class Viscosity SAE30, SAE10W-30 Capacity [When engine is completely dry] 0.65 L (0.69 US-qt) Level Operating range (grid area) on dipstick Item Service Limit Oil Pump: Inner and outer rotor clearance 0.14 mm (0.006 in.) Outer rotor outside diameter 22.940 mm (0.9031 in.) Outer rotor thickness 11.960 mm (0.4709 in.) Pump housing inside diameter 23.241 mm (0.915 in.) Pump housing depth 12.220 mm (0.
6-6 LUBRICATION SYSTEM Engine Oil CAUTION Engine operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure and accident. Before starting the engine for the first time, add oil: The engine is shipped dry. Preoil the engine to force all air from the internal oil passages. fresh engine oil to the specified level (see Periodic • Fill Maintenance chapter). the engine at slow speed 2 minutes. • Run Stop • the engine and check the oil level.
LUBRICATION SYSTEM 6-7 Lubrication System Pressure the oil of oil pump is elevate the oil passages of crankcase of thread. Discharge the oil camshaft to side from crank celing side and the revolution of the camshaft to dissemination the oil mist from the crankshaft chamber. Lubrication the piston and big end, small end, shaft, gear.
6-8 LUBRICATION SYSTEM Oil Pump Oil Pump Removal • Remove: Air Cleaner (see Fuel System chapter) • Recoil Starter (see Electrical System chapter) Fuel Tank (see Fuel System chapter) Flywheel (see Electrical System chapter) Crankcase Cover (see Camshaft/Crankshaft chapter) Camshaft (see Camshaft/Crankshaft chapter) Connecting Rod (see Camshaft/Crankshaft chapter) Crankshaft (see Camshaft/Crankshaft chapter) Remove the oil pump assembly [A].
LUBRICATION SYSTEM 6-9 Oil Pump the inside diameter [A] of the pump housing with • Measure an inside micrometer at several points. If the inside diameter is more than the service limit, replace the crankcase. Pump Housing Inside Diameter Service Limit: 23.241 mm (0.915 in.) the depth [B] of the pump housing with a depth • Measure micrometer at several points. If any of measurement is more than the service limit, replace the crankcase. Pump Housing Depth Service Limit: 12.220 mm (0.4811 in.
CAMSHAFT/CRANKSHAFT 7-1 Camshaft/Crankshaft TABLE OF CONTENTS Exploded View........................................................................................................................... Specifications ............................................................................................................................ Crankcase ................................................................................................................................. Crankcase Cover Removal ........
7-2 CAMSHAFT/CRANKSHAFT Exploded View
CAMSHAFT/CRANKSHAFT 7-3 Exploded View Torque No. 1 2 3 4 Fastener Crankcase Cover Bolts Connecting Rod Big End Cap Bolts Valve Clearance Lock Screws Rocker Arm Bolts G: Apply grease. O: Apply engine oil. S: Follow the specific tightening sequence. N·m 8.8 5.9 6.9 28 kgf·m 0.90 0.60 0.70 2.
7-4 CAMSHAFT/CRANKSHAFT Specifications Item Camshaft, Tappet: Cam lobe height Camshaft journal diameter Camshaft hole inside diameter Crankshaft, Connecting Rod: Connecting rod bend Service Limit Intake, Exhaust PTO side Flywheel side 22.060 mm (0.8685 in.) 7.77 mm (0.3059 in.) 13.927 mm (0.5483 in.) Crankcase cover 11.060 mm (0.4354 in.
CAMSHAFT/CRANKSHAFT 7-5 Crankcase Crankcase Cover Removal the oil (see Lubrication System chapter). • Drain Remove: • Air Cleaner (see Fuel System Chapter) • Recoil Starter (see Electrical System Chapter) Fuel Tank (see Fuel System Chapter) Flywheel (see Electrical System Chapter) Unscrew the mounting bolts [A] and remove the crankcase cover [B] from the crankcase. There are two knock pins on the crankcase mating surface. A wooden or plastic mallet may be used to gently tap loose the crankcase cover.
7-6 CAMSHAFT/CRANKSHAFT Crankcase the crankcase cover and tighten the crankcase • Install cover bolts following the tightening sequence shown. Torque - Crankcase Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) Do not turn one bolt down completely before the others, as it may cause the crankcase cover to warp. Inspection the inside diameter [A] of the PTO shaft hole • Measure on the crankcase cover at several points. Replace the crankcase cover if the inside diameter is more than the service limit.
CAMSHAFT/CRANKSHAFT 7-7 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. Valve controls direction of air flow caused by piston movement so that air flow from inside to outside can pass reed valve but not from outside to inside. Blow-by gas in crankcase passes through valve and expands in valve chamber. The air passes through expands in breather chamber.
7-8 CAMSHAFT/CRANKSHAFT Breather Breather Chamber Cover Removal • Remove the bolts [A] and breather chamber cover [B]. Breather Chamber Cover Installation a new gasket and the breather chamber cover, and • Install tighten the bolts. Breather Valve Inspection the breather valve [A]. • Remove Inspect the breather valve [A] for breakage, hair crack or • distortion, replace it if necessary. the valve seating surface. The surface should be • Inspect free of nicks or burrs.
CAMSHAFT/CRANKSHAFT 7-9 Camshaft, Tappet Camshaft, Tappet Removal the oil (see Lubrication System chapter). • Drain Remove: • Air Cleaner (see Fuel System chapter) Recoil Starter (see Electrical System chapter) Fuel Tank (see Fuel System chapter) Flywheel (see Electrical System chapter) Crankcase Cover (see Crankcase Cover Removal) Rocker Cover [A] the piston TDC at the end of the compression • Position stroke in. down [A] the spring side of the rocker arm [B] and • Push move it to clear the push rod [C].
7-10 CAMSHAFT/CRANKSHAFT Camshaft, Tappet Camshaft, Tappet Installation engine oil to the following. • Apply Tappet Journal • • • • • • • Camshaft Journal Cam Lobe Surface Camshaft Gear Install the tappets in those old positions. Align the punch marks [A] on the crankshaft gear and on the camshaft gear. Install the push rods (see Push Rod Installation). Install the rocker arms on the push rods, and install the valve clearance adjust nuts. Adjust the valve clearance (see Engine Top End chapter).
CAMSHAFT/CRANKSHAFT 7-11 Camshaft, Tappet the camshaft to make sure that its automatic com• Inspect pression Reduction (ACR) function operates smoothly and does not have any damage or abnormal wear. If ACR parts are worn, replace the ACR with a new one. When the weight [A] is closed, if the top of the arm [B] is lower than the base [C], replace the ACR with a new one.
7-12 CAMSHAFT/CRANKSHAFT Crankshaft, Connecting Rod Connecting Rod Removal • Remove: Piston (see Engine Top End chapter) Connecting Rod Installation • Install: Piston (see Engine Top End chapter) Crankshaft Removal the oil (see Lubrication System chapter).
CAMSHAFT/CRANKSHAFT 7-13 Crankshaft, Connecting Rod Connecting Rod Bend/Twist connecting rod bend. • Measure Select an arbor of the same diameter as the connecting rod big end, and insert the arbor through the connecting rod big end. Select an arbor of the same diameter as the piston pin and at least 100 mm long, and insert the arbor through the connecting rod small end. On a surface plate, set the big-end arbor on V blocks [A].
7-14 CAMSHAFT/CRANKSHAFT Crankshaft, Connecting Rod the crankpin width [A] with a dial caliper. • Measure If the crankpin width is more than the service limit, replace the crankshaft. Crankpin Width Service Limit: 24.17 mm (0.95 in.) Connecting Rod Big End Bearing/Crankpin Wear a light film of oil on the thread of the cap bolts. • Apply Install cap bolts and tighten the bolts to the specified • torque the (see Piston Installation in Engine Top End chap- • ter).
CAMSHAFT/CRANKSHAFT 7-15 Crankshaft, Connecting Rod Crankshaft Main Journal/Wear both journals at several points around the jour• Measure nal circumference. If the journal diameter is less than the service limit, replace the crankshaft with a new one. PTO Side Crankshaft Journal Diameter [A] Service Limit: 27.96 mm (1.101 in.) Flywheel Side Crankshaft Journal Diameter [B] Service Limit: 27.98 mm (1.102 in.
ELECTRICAL SYSTEM 8-1 Electrical System TABLE OF CONTENTS Exploded View........................................................................................................................... Specifications ............................................................................................................................ Special Tools ............................................................................................................................. Wiring Diagram .....................
8-2 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 8-3 Exploded View Torque No. 1 2 3 4 5 6 7 8 Fastener Flywheel Bolt Recoil Starter Set Screw Spark Plug Brake Arm Mounting Bolt Fuel Tank Cover Bolts Recoil Starter Mounting Bolts Brake Lever Assembly Mounting Bolt Kill Switch Bolt DO: Degrease the taper. N·m 42 1.0 22 9.3 6.9 6.9 6.9 1.5 kgf·m 4.3 0.10 2.2 0.95 0.70 0.70 0.70 0.15 ft·lb 31 8.
8-4 ELECTRICAL SYSTEM Specifications Item Ignition System: Ignition coil: Primary winding resistance Secondary winding resistance Spark Plug Plug gap Standard in the text in the text NGK BPR5ES 0.75 mm (0.030 in.
ELECTRICAL SYSTEM 8-5 Special Tools Hand Tester: 57001–1394 Bracket Holder: 57001–1536
8-6 ELECTRICAL SYSTEM Wiring Diagram
ELECTRICAL SYSTEM 8-7 Precautions There are a number of important precautions that must be taken when servicing electrical systems. Learn and observe all the rules below. The electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them. Troubles may involve one or in some cases all items. Never replace a defective part without determining what CAUSED the failure.
8-8 ELECTRICAL SYSTEM Charging, Ignition System Flywheel Removal • Remove: Air Cleaner (see Fuel System chapter) Recoil Starter (see Electrical System chapter) Fuel Tank (see Fuel System chapter) the pulley [B] with a bracket holder [A], remove the • Hold flywheel bolt and washer. Special Tool - Bracket Holder: 57001–1536 • Remove the pulley. the fan housing bolts [A] and remove the fan • Loosen housing [B] and screen [C]. • Remove the fan.
ELECTRICAL SYSTEM 8-9 Charging, Ignition System • Remove: Woodruff Key [A] Flywheel Installation a cleaning fluid, clean off any oil or dirt on the fol• Using lowing portions and dry them with a clean cloth. • • Crankshaft Tapered Portion [A] Flywheel Tapered Portion [B] Degrease the flywheel taper, crankshaft taper, before assembring. Fit the Woodruff key [C] securely in the slot in the crankshaft before installing the flywheel.
8-10 ELECTRICAL SYSTEM Charging, Ignition System the pulley [A] and washer [B]. • Install Tighten the flywheel bolt [C]. • Torque - Flywheel Bolt: 42 N·m (4.3 kgf·m, 31 ft·lb) the washer [A] as shown. • Install Flywheel Bolt [B] • Install the other removed parts.
ELECTRICAL SYSTEM 8-11 Charging, Ignition System Circuit Composition Co: Ignition Coil Core C: Condenser D1: Diode D2: Diode D3: Diode E: Exciter Coil L1: Primary Coil L2: Secondary Coil SCR: Thyristor SP: Spark Plug Action Principle (1) Fundamental action 1. Genarated positive direction voltage by rotor rotated in the exciter coil (E) flow the electrical current through the diode (D1), and discharged to the condenser (C). 2.
8-12 ELECTRICAL SYSTEM Charging, Ignition System Cautions of handling and maintenance (1) Do not near the magnet by the heat of fire. (2) Ignition timing is no adjustment because of it is fixed. (3) When carry out the spark test, pull the recoil starter knob with strong force. If the flywheel does not turned more than the ignition revolutions, spark does not ignite.
ELECTRICAL SYSTEM 8-13 Charging, Ignition System Ignition Coil Inspection the ignition coil (see Ignition Coil Removal). • Remove Measure the winding resistance as follows. • Set the hand tester to the R × 1 k range. Special Tool - Hand Tester: 57001–1394 Make the measurements shown in the table. Ignition Coil Winding Resistance CAUTION Use only Tester 57001–1394 with new battery at room temperature for this test. A tester other than the Kawasaki Hand Tester should show different readings.
8-14 ELECTRICAL SYSTEM Starter System Recoil Starter Removal • Remove: Recoil Starter Mounting Bolts [A] Recoil Starter [B] Recoil Starter Installation • Install the recoil starter and tighten the mounting bolts. Torque - Recoil Starter Mounting Bolts: kgf·m, 61 in·lb) 6.9 N·m (0.70 Recoil Starter Disassembly the recoil starter (see Recoil Starter Removal). • Remove Pull the starter [A] 30 cm (1 ft), and clamp the rope • [B] with the clipknob [D] so it can not wind back onto the reel • • [C].
ELECTRICAL SYSTEM 8-15 Starter System WARNING When removing the reel [A], be careful that the spiral spring [B] in the reel does not fly loose and cause injury. The spring is under great pressure. NOTE There should be no spring tension on the reel when removing it. If tension is felt, push the reel back into place and gently “wiggle” it until the reel can be easily removed. • Slowly lift the reel straight up out of the case [C].
8-16 ELECTRICAL SYSTEM Starter System the tape. • Remove Install: • Ratchets [A] Friction Spring [B] the ratchet guide [A]. • Install Tighten the set screw [B]. • Torque - Recoil Starter Set Screw: 1.0 N·m (0.10 kgf·m, 8.9 in·lb) the reel two turns counterclockwise to preload the • Turn spiral spring. holding the reel to keep it from unwinding, feed the • While end of the rope through the hole in the case. [A] the rope as shown to hold it. • Clip the starter knob [B] and secure it with a knot [C].
ELECTRICAL SYSTEM 8-17 Pad Brake Pad Brake Assembly Removal • Remove: Air Cleaner (see Fuel System chapter) Recoil Starter (see Electrical System chapter) Fuel Tank (see Fuel System chapter) Pulley (see Flywheel Removal) Fan Housing and Fan (see Flywheel Removal) the brake lever assembly mounting bolt [A]. • Remove Remove spring [B] from the lever assembly and re• move thethe lever assembly [C]. • Remove the spring [B] and bolt [D]. the earth read wire from the ignition coil. • Remove Remove • chapter).
8-18 ELECTRICAL SYSTEM Pad Brake the bolt [A]. • Tighten Install the assembly [B]. • Tighten thelever brake lever assembly mounting bolt [C]. • Torque - Brake Lever Assembly Mounting Bolt: 6.9 N·m (0.70 kgf·m, 61 in·lb) • • • Check the lever assembly move smoothly was installed. Install the spring [D]. Install the other removed parts. Adjust the high idle speed to the specifications (see Periodic Maintenance chapter).
TROUBLESHOOTING 9-1 Troubleshooting TABLE OF CONTENTS Engine Troubleshooting Guide ..................................................................................................
9-2 TROUBLESHOOTING Engine Troubleshooting Guide If the engine malfunctions, check if the way the engine is used is correct. If engine malfunctions even if engine is used correctly, systematically carry out troubleshooting starting with simple points. This chart describes typical troubleshooting procedures. It’s not necessary to disassemble carburetor, magneto or engine unless it has been found to be the cause of the malfunction.
TROUBLESHOOTING 9-3 Engine Troubleshooting Guide
9-4 TROUBLESHOOTING Engine Troubleshooting Guide
TROUBLESHOOTING 9-5 Engine Troubleshooting Guide
