Service Manual

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FH381V FH430V

4–stroke air cooled v-twin gasoline engine

Service Manual

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.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been

taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such

changes to products manufactured previously.

All information contained in this publication is based on the latest product information available at the time of publication.

Illustrations and photographs in this publication are intended for reference use only and may not depict actual model

component parts.

Summary of content (124 pages)

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FH381V FH430V 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 Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
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LIST OF ABBREVIATIONS A ampere(s) lb pound(s) ABDC AC ATDC BBDC BDC BTDC C DC F F ft g h L 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) m min N Pa PS psi r rpm TDC TIR V W meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) per minute top dead center total indicat
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EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission Emission Control System 1. Crankcase (2) control systems (EM) in compliance applicable the to United States Environmental Protection A sealed-type crankcase with emission controlregulations system is of used eliminate blow-by gases. The blow-byAgency and California Air Resources gases are led to Board. the breather chamber through the crankcase.
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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.
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GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing................................................................................................................................................................1-2 Model Identification ........................................................................................................................................................... 1-4 General Specifications .................................................................
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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.
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GENERAL INFORMATION 1-3 Before Servicing (15) Cotter Pin Replace any cotter pins that were removed with new ones, as removal deforms and breaks them. (16) Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old grease and dirty oil should be cleaned off.
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1-4 GENERAL INFORMATION Model Identification Electric Starter Model Recoil Starter Model Cylinder Number Designation: No.1 Cylinder is the left-hand cylinder viewed from the air cleaner. No.2 Cylinder is the right-hand cylinder viewed from the air cleaner.
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GENERAL INFORMATION 1-5 General Specifications Items FH381V, FH430V Type of engine Forced air-cooled, vertical shaft, OHV, 4-stroke gasoline engine. Cylinder layout 90 V-Twin Bore x Stroke 65 mm x 65 mm (2.56 in x 2.56 in) Piston displacement 431 mL (26.3 cu.
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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.
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GENERAL INFORMATION 1-7 Torque and Locking Agent Fastener Lubrication System: Engine Drain Plugs Oil Passage Plug Oil Pump Cover Plate Mounting Bolts Oil Filter Camshaft/Crankshaft: Crankcase Cover Bolts Breather Chamber Cover Bolts Electrical System: Starter Coil Screws Flywheel Bolt Fan Housing Bolts Screen Screws Regulator Screws Ignition Coil Bolts (Studs) Ignition Coil Bolts (Bolts) Starter Motor Mounting Bolts Starter Motor Through Bolts Recoil Starter Mounting Nuts Recoil Starter Retainier Screw Spar
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1-8 GENERAL INFORMATION Special Tools Piston Ring Pliers: 57001–115 Piston Ring Compression Belt, Ø55 – Ø67: 57001–1096 Oil Pressure Gauge, 5kgf/cm2: 57001–125 Valve Seat Cutter, 45 - Ø27.5: 57001–1114 Compression Gauge: 57001–221 Valve Seat Cutter, 32 - Ø25.0: 57001–1118 Oil Pressure Gauge Adapter, PT 1/8: 57001–1033 Valve Seat Cutter, 32 - Ø28.
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GENERAL INFORMATION 1-9 Special Tools Compression Gauge Adapter M14 x 1.
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PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart..............................................................................................................................................2-2 Specifications .................................................................................................................................................................... 2-3 Periodic Maintenance Procedures............................................................
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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.
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PERIODIC MAINTENANCE 2-3 Specifications Item Standard Fuel System Idle speed: (1) Low idle speed 1550 r/min (rpm) High idle speed 3600 r/min (rpm) Air cleaner: Type Dual stage filtration system Pre-cleaner Foam element Second-stage cleaner Paper element Engine Top End Valve clearance Intake, Exhaust 0.10 ~ 0.15 mm (0.004 ~ 0.006 in.) Valve seating surface angle Intake, Exhaust 45 Valve seating surface width Intake, Exhaust 0.6 ~ 0.9 mm (0.024 ~ 0.035 in.
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2-4 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Low Idle Speed Adjustment all possilble external loads from the engine. • Disconnect • Start the engine and warm it up thoroughly. Always keep your hands clear of the moving parts. the throttle lever on dash to the idle position, and hold the • Move throttle lever on the carburetor in closed position (turn the governor arm clockwise all the way) and adjust the low idle speed screw [A] until the engine idles at specified speed.
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PERIODIC MAINTENANCE 2-5 Periodic Maintenance Procedures Fuel system Cleanliness Inspection Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. the air cleaner (see Fuel System chapter). • Remove a suitable container [A] under the float chamber mounting bolt • Place [B] on the carburetor.
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2-6 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Element Removal • Push down the latches [A] and remove the air cleaner case [B]. • Remove: Paper Element [A] Foam Element [B] Air Element Installation the element correctly on the air cleaner case. • Install sure the foam element is in-place in the air cleaner case. • Be sure the paper element is in-place in the air cleaner case. • Be Install cleaner case on the air cleaner body.
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PERIODIC MAINTENANCE 2-7 Periodic Maintenance Procedures the foam element and the paper element. • Remove Clean the element [A] in a bath of detergent and water, and let • the elementfoam air-dry throughly before installing it. the paper element [A] by tapping it gently on a flat surface to • Clean remove dust. If the element is very dirty, replace it with a new one. CAUTION Do not use compressed air to clean the paper element. Do not oil the paper or foam element.
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2-8 PERIODIC MAINTENANCE Periodic Maintenance Procedures Valve Clearance Inspection NOTE Valve clearance must be checked when the engine is cold (at room temperature). the rocker cover (see Engine Top End chapter). • Remove Place the at top dead center (TDC) of the compression stroke • turning thepiston crankshaft clockwise facing the flywheel. No.1 Cylinder: The left projection [A] on the flywheel is faced with the right leg [B] on the #1 ignition coil [C] as shown.
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PERIODIC MAINTENANCE 2-9 Periodic Maintenance Procedures Valve Seat Inspection the valve (see Engine Top End chapter). • Remove Inspect the seats for damage. • If the seats valve are warped or distorted beyond reconditioning, replace • • • • • the cylinder head. Pitted or worn valve seats can be refaced. Lap the valves to the seats after refacing. Coat the valve seat with machinist’s dye. Push the valve into the guide. Rotate the valve against the seat with a lapping tool.
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2-10 PERIODIC MAINTENANCE Periodic Maintenance Procedures Marks Stamped on the Cutter: The marks stamped on the back of the cutter represent the following. 1 30 Cutter number, selected from 1 to 12 Cutter angle [A] 37.5 Cutter diameter of cutter [B] KS8B Manufactured lot number Operating Procedures: Clean the seat area carefully. Recondition the valve seats with the valve seat cutters (45 , 32 ) and lap the valves. Check the seats for good contact all the way around with machinist’s dye.
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PERIODIC MAINTENANCE 2-11 Periodic Maintenance Procedures the face of valve sparingly with a fine lapping compound. • Coat Use the cup tool [A], to grip top of the valve [B]. Rotate the • valve in avacuum circular motion to lap the valve to the seat. the valve slightly from the seat every 8 to 10 strokes, continue • Lift lapping operation until a uniform ring appears around entire surface of the valve face. lapping is completed, wash all parts in solvent to remove • When lapping compound.
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2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Oil Change the oil after first 8 hours of operation. Thereafter change oil • Change every 100 hours. and warm up the engine so the oil will drain easily. Stop the • Start engine. the engine on a level surface. • Place Place container under the engine. • Removea suitable the drain plug [A] and drain the oil. • Be careful of hot oil when drained. It may be hot enough to burn you severely. the O-ring [B] at the drain plug for damage.
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PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Electrical System Spark Plug Cleaning and Inspection the spark plug (See Electrical System chapter). • Remove If the plug is oily or has carbon build up on it, clean the plug using a high flash-point solvent and a wire brush or other suitable tool. If the spark plug electrodes are corroded or damaged, or if the insulator is cracked, replace the plug. Use the standard spark plug or its equivalent.
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FUEL SYSTEM 3-1 Fuel System Table of Contents Exploded View...................................................................................................................................................................3-2 Specifications .................................................................................................................................................................... 3-4 Governor Link Mechanism..............................................................................
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3-2 FUEL SYSTEM Exploded View 1. Pilot Screw 2. Main Jet T1: T2: T3: T4: T5: 0.7 2.3 4.5 5.9 6.9 Nm Nm Nm Nm Nm (0.07 (0.23 (0.46 (0.60 (0.70 kgf m, kgf m, kgf m, kgf m, kgf m, 6 in lb) 20 in lb) 40 in lb) 52 in lb) 61 in lb) L: Apply non-permanent locking agent. O: Apply engine oil. S: Follow the specific tightening sequence.
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FUEL SYSTEM 3-3 Exploded View T1: 2.0 N1m (0.20 kgf1m , 18 in1lb) T2: 5.9 N1m (0.60 kgf1m , 52 in1lb) T3: 7.8 N1m (0.80 kgf1m , 69 in1lb) O: Apply engine oil.
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3-4 FUEL SYSTEM Specifications Standard Item FH381V FH430V Caburetors Specifications: Make/ type Walbro LMF-2 Walbro LMF-1 Throttle bore diameter 24 mm (0.94 in.) Venturi diameter 14 mm (0.55 in) 16 mm (0.63 in.
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FUEL SYSTEM 3-5 Governor Link Mechanism Control Panel Assembly Removal • Remove: Air Cleaner (see Cleaner Body Removal) Control Panel Mounting Bolts [A] the control panel assembly [A] while unhooking the governor • Remove spring [B] end loop at the panel bracket. • Clear the choke link rod lower end [C] from the choke lever.
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3-6 FUEL SYSTEM Governor Link Mechanism Governor Arm Installation the governor arm [A] onto the governor shaft [B] temporarily. • Install Be sure link spring [C] around the throttle link rod [D] is in place • and that the 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 to fully open the carburetor [G] throttle valve and hold it there.
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FUEL SYSTEM 3-7 Governor Link Mechanism Governor Assembly Inspection Visually check all governor parts for wear and damage. If any parts are worn or damaged, replace them. Governor Shaft Removal the crankcase (see Camshaft/Crankcase chapter). • Split Unscrew the governor shaft plate screws [A], and pull out the governor • shaft [B] outside. NOTE It is not necessary to remove the governor shaft unless it is being replaced.
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3-8 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 heavy load conditions. Fuel flows through the main jet and into the main nozzle, where it is joined by air from the main air passage (main air jet).
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FUEL SYSTEM 3-9 Carburetor Low Idle Speed Adjustment Refer to Low Idle Speed Adjustment in the Periodic Maintenance Chapter (2nd chapter). 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.
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3-10 FUEL SYSTEM Carburetor Carburetor Removal Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well- ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. • Remove: Air Cleaner and Related Parts (see Cleaner Body). Turn shut off valve to the OFF position. • Drainthethefuel carburetor. • Disconnect the fuel tube at the fuel inlet joint [A] of the carburetor.
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FUEL SYSTEM 3-11 Carburetor Carburetor Disassembly/Assembly to the illustration shown for disassembly and assembly. • Refer There several passage plugs (Ball plugs) in the carburetor body. • Do notare remove. disassembly, mark the out side of choke valve and throttle • Before valves for assembling them. the pilot screw in accordance with the following procedure if • Replace necessary.
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3-12 FUEL SYSTEM Carburetor Carburetor Cleaning Clean the carburetor in a well-ventilated area, and take care that there is no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low flash-point solvents to clean the carburetors. CAUTION Do not use compressed air on an assembled carburetor, or the floats may be crushed by the pressure.
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FUEL SYSTEM 3-13 Carburetor the float [A] assembly installed onto the carburetor body [B], • With hold the carburetor upside down at eye level. Gently support the float with a finger and bring it down slowly so that the float arm tab [C] just touches the float valve [D]. The float lower surface [E] should be parallel with the carburetor body mating surfaces [F]. If the float position is not correct, replace the float with a new one. the float valve for excessive wear or damage.
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3-14 FUEL SYSTEM Intake Manifold Intake Manifold Removal • Remove: Air Cleaner (see Cleaner Body Removal) • • Engine Upper Cover Carburetor (see Carburetor Removal) Remove the harness from the clamps [A] on the intake manifold. Unscrew the manifold mounting bolts [B]. Intake Manifold Installation the O-rings [A] with new ones. • Replace Clean the mating surfaces of the cylinders and intake manifolds.
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FUEL SYSTEM 3-15 Intake Manifold Intake Manifold Inspection the intake manifold for cracks. • Inspect Cracks not visible to the eye may be detected by using a metal crack • detection system. (Visual color check: commonly found at automotive • parts store.) If a crack is present in the intake manifold, replace it. Inspect the gasket surfaces for burrs and nicks.
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3-16 FUEL SYSTEM Fuel Pump, Fuel Filter The fuel pump cannot be disassembled, if any damage to the pump is noticed replace it with a new one. Fuel Pump Inspection Refer to Fuel Pump Inspection in the Periodic Maintenance Chapter (2nd chapter). Fuel Filter Inspection Refer to Fuel Filter Inspection in the Periodic Maintenance Chapter (2nd chapter).
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FUEL SYSTEM 3-17 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 the elements (see Periodic Maintenance chapter). • Remove Remove • [B].
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COOLING SYSTEM 4-1 Cooling System Table of Contents 4 Exploded View...................................................................................................................................................................4-2 Cooling Fan.......................................................................................................................................................................4-3 Cooling Fan Removal...........................................................................
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4-2 COOLING SYSTEM Exploded View T1: T2: T3: T4: T5: 3.4 N1m (0.35 kgf1m, 30 in1lb) 5.9 N1m (0.60 kgf1m, 52 in1lb) 7.8 N1m (0.80 kgf1m, 69 in1lb) 15 N1m (1.5 kgf1m, 11 ft1lb) 56 N1m (5.
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COOLING SYSTEM 4-3 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 cooling fan. • If any mud or dust have stuck to the cooling fan, clean it. Cooling fan is cleaned by washing in detergent and water.
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ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View...................................................................................................................................................................5-2 Specifications .................................................................................................................................................................... 5-4 Cylinder Head..................................................................................
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5-2 ENGINE TOP END Exploded View T1: T2: T3: T4: T5: 5.9 N1m (0.60 kgf1m, 52 in1lb) 6.9 N1m (0.70 kgf1m, 61 in1lb) 22 N1m (2.2 kgf1m, 16 ft1lb) 25 N1m (2.6 kgf1m, 19 ft1lb) 28 N1m (2.8 kgf1m, 20 ft1lb) O: Apply engine oil. G: Apply grease. S: Follow the specific tightening sequence.
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ENGINE TOP END 5-3 Exploded View T1: 15 N1m (1.
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5-4 ENGINE TOP END Specifications Item Service Limit Cylinder Head: Cylinder compression (MIN) [390 kPa (57 psi)] (MIN) Cylinder head warp 0.03 mm (0.001 in.) Valves: Valve head thickness Intake, Exhaust 0.35 mm (0.014 in.) Valve stem runout Intake, Exhaust 0.05 mm (0.002 in.) Valve stem diameter Intake 5.95 mm (0.0234 in.) Exhaust 5.93 mm (0.0233 in.) Valve guide inside diameter Intake, Exhaust 6.08 mm (0.239 in.) Valve spring free length Intake, Exhaust 31.5 mm (1.24 in.
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ENGINE TOP END 5-5 Cylinder Head Compression Measurement measuring compression, do the following: • Before Be sure the battery is fully charged. • • Thoroughly warm up the engine so that engine oil between the piston and cylinder wall will help seal compression as it does during normal running. Stop the engine. Disconnect the spark plug caps of each cylinder and remove the spark plugs. Attach the compression gauge assembly firmly into one plug hole.
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5-6 ENGINE TOP END Cylinder Head Cylinder Head Assembly Removal • Remove: Air Cleaner and Carburetor (see Fuel System chapter) • Muffler (see Muffler Exhaust Pipe Removal) Intake Manifold (see Fuel System chapter) Spark Plug Unscrew the rocker cover mounting bolts [A], and remove the cover [B] and gasket. removing the #1, #2 cylinder head, set each cylinder at T.D.C • When [A] of power stroke in. • Loosen the cylinder head bolts 1/4 turn in the sequence shown.
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ENGINE TOP END 5-7 Cylinder Head Push Rod Removal each cylinder at T.D.C of power stroke. • Set Remove rocker covers (see Cylinder Head Assembly Removal). • Loosen thethevalve clearance adjusting nuts [A]. • Move the rocker arms • Pull out the push rods.[B] to clear the push rod upper ends. • NOTE Mark the push rods so they can be installed in their original position during assembly. Push Rod Installation each cylinder at T.D.C of power stroke.
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5-8 ENGINE TOP END Cylinder Head Push Rod Inspection the rocker arm push rod in V blocks that are as far apart as • Place possible, and set a dial gauge on the rod at a point halfway between the blocks. Turn the rod to measure the runout. The difference between highest and the lowest dial readings is the amount of runout. If the runout exceeds the service limit, replace the rod. Rocker Arm Push Rod Runout Service Limit: 0.5 mm (0.02 in.
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ENGINE TOP END 5-9 Cylinder Head Cleaning and Inspection Refer to Cylinder Head Cleaning and Inspection in the Periodic Maintenance Chapter (2nd chapter). Rocker Arm Inspection and inspect the rocker arm where it touches the push rod and • Clean valve stem. If the contact points [A] are worn or damaged, replace the rocker arm.
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5-10 ENGINE TOP END 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).
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ENGINE TOP END 5-11 Valves Valve Spring Inspection the valve spring for pitting, cracks, rusting, and burns. • Inspect Replace the spring if necessary. the free length [A] of the spring. • Measure If the measurement is less than the service limit, replace the spring. Valve Spring Free Length Service Limit: 31.5 mm (1.24 in.
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5-12 ENGINE TOP END Cylinder, Piston Piston Removal the crankcase (see Camshaft/Crankshaft chapter). • Split Remove camshaft (see Camshaft/Crankshaft chapter). • Turn the the crankshaft to expose the connecting rod cap bolts [A]. • Remove the bolts and take off the connecting rod caps [B]. • NOTE Note the position of the connecting rod caps for reinstalling the caps. the connecting rod end into the cylinder, and pull the piston and • Push connecting rod out of the cylinder.
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ENGINE TOP END 5-13 Cylinder, Piston Piston Installation the expander [A] in the piston oil ring groove so that the • Install expander ends [B] touch together, never overlap. the upper and lower steel rails. There is no UP or Down to the • Install rails. They can be installed either way. not mix up the top and second rings. • Do Install second ring so that the “0” mark faces up. • Install the the top ring. • The rings should • [A] Piston Head turn freely in the grooves.
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5-14 ENGINE TOP END Cylinder, Piston engine oil to the piston skirt and the cylinder bore. • Apply 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: 57001–1096 the piston and connecting rod so that the arrow mark [A] on • Insert the top of the piston is facing the flywheel side [B].
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ENGINE TOP END 5-15 Cylinder, Piston Piston Cleaning • Remove the piston and piston rings (see Piston Removal). CAUTION Never clean the piston head with the engine assembled. Carbon particles will fall between the piston and cylinder, and damage the crankshaft bearings. the carbon off [A] the piston head. • Scrape the scraping tools carefully. Do not gouge the piston head. To • Use avoid gouging, use scrapers that are made of a material that will not cause damage.
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5-16 ENGINE TOP END Cylinder, Piston Piston Ring End Gap the piston rings. • Remove Push each at a time) in the cylinder bore to a point close • to the bottomringof (one the cylinder bore. • Use the piston to push it in to be sure it is square. Measure the gap [A] between the ends of the ring [B] with a thickness gauge. If the end gap of any ring is greater than the service limit, replace the entire set of rings. Piston Ring End Gap Service Limit Top 0.75 mm (0.029 in.) Second 0.75 mm (0.029 in.
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ENGINE TOP END 5-17 Cylinder, Piston Piston Diameter the outside diameter [A] of the piston 12.5 mm (0.9 in.) up • Measure [B] from the bottom of the piston at a right angle to the direction of the piston pin hole. If the measurement is less than the service limit, replace the piston. Piston Diameter Service Limit: 64.79 mm (2.551 in.) 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.
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5-18 ENGINE TOP END Cylinder, Piston Change to a honing stone for finishing, the final bore diameter should be as shown in the table. Be sure the correct stone is used and the stone is not worn. Clean the cylinder at the top and bottom of the cylinder to remove burns and pieces of the base and head gasket. Anchor the cylinder (block) on the drill press table before honing. Align the center of the cylinder bore to the press center. Set the press to operate from 200 to 250 rpm.
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ENGINE TOP END 5-19 Muffler/Exhaust Pipe Installation Muffler/Exhaust Pipe Removal the clamp nut [A]. • Loosen Remove the bolt [B] on the muffler bracket and take off the muffler. • the exhaust pipe flange nuts [A], and remove the exhaust • Unscrew pipe [B] with pipe cover [C]. Use a penetrating oil if necessary to break threads loose. the gaskets. • Remove Unscrew hook nut [D], separate the exhaust pipe and pipe cover.
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LUBRICATION SYSTEM 6-1 Lubrication System Table of Contents Exploded View...................................................................................................................................................................6-2 Engine Oil Flow Chart.......................................................................................................................................................6-3 Specifications ................................................................................
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6-2 LUBRICATION SYSTEM Exploded View T1: T2: T3: T4: 3.9 N1m (0.40 kgf1m, 35 in1lb) 5.9 N1m (0.60 kgf1m, 52 in1lb) 6.9 N1m (0.70 kgf1m, 61 in1lb) See the text O: Apply engine oil.
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LUBRICATION SYSTEM 6-3 Specifications
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6-4 LUBRICATION SYSTEM Specifications Item Standard Engine Oil: Type SF, SG, SH or SJ class Viscosity SAE40, SAE30, SAE10W-30/SAE10W-40, or SAE5W-20 Capacity [When filter is not removed] 1.5 L (1.6 US qt) [When filter is removed] 1.7 L (1.8 US qt) Level Operating range (grid area) on dipstick Oil Pressure 241 to 310 kPa (35 to 45 psi)/3000 rpm Oil Filter By-pass Valve Openning Pressure 78.5 Item 117.5 kPa (11.4 17.1 psi) Service Limit Oil Pump: Inner and outer rotor clearance 0.2 mm (0.
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LUBRICATION SYSTEM 6-5 Engine Oil and Oil Filter 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 and the oil filter. fresh engine oil to the specified level (see Periodic Maintenance • Fill chapter). the engine at slow speed 2 minutes.
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6-6 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.
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LUBRICATION SYSTEM 6-7 Oil Pump, Relief Valve Oil Pump, Relief Valve Removal the crankcase cover (see Camshaft/Crankshaft chapter). • Remove Unscrew the mounting bolts and remove the oil pump parts assembly • (pump gear, pump cover plate, pump shaft, pins and rotors). off the relief valve spring and ball. • Take the pump parts assembly.
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6-8 LUBRICATION SYSTEM Oil Pump, Relief Valve the inside diameter [A] of the pump housing with an inside • Measure micrometer at several points. If the inside diameter is more than the service limit, replace the crankcase cover. Pump Housing Inside Diameter Service Limit: 40.801 mm (1.6063 in.) the depth [B] of the pump housing with a depth micrometer • Measure at several points. If any of measurement is more than the service limit, replace the crankcase cover. Pump Housing Depth Service Limit: 10.
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LUBRICATION SYSTEM 6-9 Oil Screen Oil Screen Removal the crankcase cover (see Camshaft/Crankcase chapter). • Remove Unscrew • assembly.the mounting bolts [A] and remove the oil pump parts • Remove the oil screen [B] Oil Screen Installation the oil screen thoroughly whenever it is removed for any reason. • Clean the oil screen [A] in position and install the oil pump parts • Insert assembly (see Oil Pump, Relief Valve Installation).
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CAMSHAFT/CRANKSHAFT 7-1 Camshaft/Crankshaft Table of Contents Exploded View...................................................................................................................................................................7-2 Specifications .................................................................................................................................................................... 7-3 Crankcase ...........................................................................
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7-2 CAMSHAFT/CRANKSHAFT Exploded View T1: 5.9 N1m (0.60 kgf1m, 52 in1lb) T2: 25 N1m (2.6 kgf1m, 19 ft1lb) T3: See Engine Top End chapter. O: G: M: SS: S: Apply engine oil. Apply grease. Apply molybdenum disulfide grease. Apply silicone sealant. Follow the specific tightening sequence.
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CAMSHAFT/CRANKSHAFT 7-3 Specifications Item Service Limit Camshaft, Tappet: Cam lobe height Camshaft journal diameter Camshaft bearing inside diameter Intake 29.131 mm (1.1469 in.) Exhaust 29.131 mm (1.1469 in.) PTO side 15.985 mm (0.6293 in.) Flywheel side 15.985 mm (0.6293 in.) Crankcase 16.136 mm (0.6352 in.) Crankcase cover 16.136 mm (0.6352 in.) Crankshaft, Connecting Rod: Connecting rod bend 0.15/100 mm (0.006/3.94 in.) Connecting rod twist 0.15/100 mm (0.006/3.94 in.
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7-4 CAMSHAFT/CRANKSHAFT Crankcase Crankcase Cover Removal the engine on a clean surface while parts are being removed. • Set Drain the oil (see Lubrication System chapter). • Remove: • Exhaust Pipe and Muffler (see Engine Top End chapter) • Control Panel (see Fuel System chapter) Governor Arm (see Fuel System chapter) When inverting the engine is necessary to remove the crankcase cover, be sure to remove the air cleaner cover and air filter elements.
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CAMSHAFT/CRANKSHAFT 7-5 Crankcase to see that the crankcase dowel pins [A] are in place on the • Check crankcase. • Install the gasket on the crankcase. the crankcase cover and tighten the crankcase cover bolts • Install following the tightening sequence shown. Torque - Crankcase Cover Bolts: 25 N1m (2.6 kgf1m, 19.0 ft1lb) Do not turn one bolt down completely before the others, as it may cause the crankcase cover to warp.
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7-6 CAMSHAFT/CRANKSHAFT Breather The function of the breather is to create a vacuum in the crankcase which prevents oil from being forced out of the engine through the piston rings, oil seals or gaskets. A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow-by gases are led to the breather chamber through the crankcase and the camshaft.
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CAMSHAFT/CRANKSHAFT 7-7 Breather Breather Chamber Cover Removal • Remove the bolts [A] and breather chamber cover [B]. Breather Chamber Cover Installation • Apply sealant [A] to the mating surface of the crankcase. Sealant - Bond Kawasaki (Silicone BondSealant) (Silicone: Sealant) 56019-120 : 56019-120 a new gasket and the breather chamber cover, and tighten the • Install bolts. Torque - Breather Chamber Cover Bolts: 5.9 N m (0.
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7-8 CAMSHAFT/CRANKSHAFT Camshaft, Tappet Camshaft, Tappet Removal the engine on a clean surface while parts are being removed. • Set Drain the oil (see Lubrication System chapter). • Remove: • Muffler (see Engine Top End chapter) Throttle Control Panel (see Fuel System chapter) Carburetor (see Fuel System chapter) Intake Manifold (see Fuel System chapter) Crankcase Cover (see Crankcase Cover Removal) Rocker Covers [A] the piston TDC at the end of the compression stroke.
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CAMSHAFT/CRANKSHAFT 7-9 Camshaft, Tappet Camshaft Disassembly the governor assembly (see Fuel System chapter). • Remove Remove: • Spring [A] Do not remove the ACR (automatic compression release) weight [B]. Camshaft Assembly the governor assembly (see Fuel System chapter). • Install After assembling check the following items. • The governor platethe[A]camshaft, must move freely. While shaking the camshaft, ACR weight [B] swings smoothly.
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7-10 CAMSHAFT/CRANKSHAFT Camshaft, Tappet the inside diameter [A] of the camshaft bearing on the • Measure crankcase at several points. This bearing is not replaceable. Replace the crankcase if the inside diameter is more than the service limit. Camshaft Bearing Inside Diameter (Crankcase) Service Limit: 16.136 mm (0.6352 in.) the inside diameter [A] of the camshaft bearing on the • Measure crankcase cover at several points. This bearing is not replaceable.
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CAMSHAFT/CRANKSHAFT 7-11 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 engine on a clean surface while parts are being removed. • Set Drain the oil (see Lubrication System chapter).
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7-12 CAMSHAFT/CRANKSHAFT Crankshaft, Connecting Rod connection rod twist. • Measure With the big-end arbor still on the V blocks, hold the connection rod horizontally and measure the amount that the small end arbor varies from being parallel with the surface plate over a 100 mm length of the arbor to determine the amount of connecting rod twist. If connection rod twist exceeds the service limit, the connecting rod must be replaced. Connecting Rod Twist Service Limit: 0.15/100 mm (0.006/3.94 in.
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CAMSHAFT/CRANKSHAFT 7-13 Crankshaft, Connecting Rod Crankshaft Runout the crankshaft runout. • Measure Set the crankshaft in a flywheel alignment jig or on V blocks gauge. Set a dial gauge against both bearing journals. Turn the crankshaft slowly to measure the runout. The difference between the highest and lowest dial gauge readings (TIR) is the amount of runout. If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Service Limit: 0.05 mm (0.002 in.
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ELECTRICAL SYSTEM 8-1 Electrical System Table of Contents Exploded View...................................................................................................................................................................8-2 Specifications .................................................................................................................................................................... 8-4 Wiring Diagram ..........................................................................
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8-2 ELECTRICAL SYSTEM Exploded View T1: T2: T3: T4: T5: 3.4 N1m (0.35 kgf1m, 30 in1lb) 5.9 N1m (0.60 kgf1m, 52 in1lb) 7.8 N1m (0.80 kgf1m, 69 in1lb) 22 N1m (2.2 kgf1m, 16 ft1lb) 56 N1m (5.
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ELECTRICAL SYSTEM 8-3 Exploded View T1: T2: T3: T4: 3.9 N1m (0.40 kgf1m, 35 in1lb) 5.9 N1m (0.60 kgf1m, 52 in1lb) 7.8 N1m (0.80 kgf1m, 69 in1lb) 15 N1m (1.5 kgf1m, 11 ft1lb) G: Apply grease. O: Apply engine oil.
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8-4 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Charging System: Regulated output voltage 14.1 V DC/3600 rpm Alternator stator coil resistance in the text Unregulated stator output 28.4 V AC/3000 rpm Regulator resistance in the text 15 V DC/3600 rpm ––– 26V AC/3000 rpm Ignition System: Ignition coil: Primary winding resistance in the text ––– Secondary winding resistance 8 to 11 k ––– Spark Plug CHAMPION RCJ8Y ––– Plug gap 0.75 mm (0.030 in.
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ELECTRICAL SYSTEM 8-5 Wiring Diagram
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8-6 ELECTRICAL SYSTEM Wiring Diagram
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ELECTRICAL SYSTEM 8-7 Wiring Diagram
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8-8 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below. Do not reverse the battery lead connections. This will burn out the diodes in the electrical parts. Always check battery condition before condemning other parts of an electrical system. A fully charged battery is a must for conducting accurate electrical system tests.
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ELECTRICAL SYSTEM 8-9 Charging, Ignition System Flywheel, Stator Coil Removal • Remove: Recoil Starter (see Recoil Starter Removal) Nuts [A] and Guard [B] Screws [C] and Screen [D] Spacer [E] • Loosen the fan housing bolts [A] and remove the fan housing [B]. • Remove: Ignition Coils (see Ignition Coil Removal) Stud Bolts [A] the flywheel with a suitable tool, remove the flywheel bolt and • Hold washer. • Using a suitable flywheel puller [A], remove the flywheel [B]. CAUTION Always use flywheel puller.
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8-10 ELECTRICAL SYSTEM Charging, Ignition System • Remove: Woodruff Key [A] Stator Coil Lead Connector [B] Stator Coil Screw [C] Stator Coil [D] Flywheel, Stator Coil Installation • Install the stator coil and tighten the screws. Torque - Stator Coil Screws: 3.4 N1m (0.35 kgf1m, 30 in1lb) a cleaning fluid, clean off any oil or dirt on the following portions • Using and dry them with a clean cloth.
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ELECTRICAL SYSTEM 8-11 Charging, Ignition System • Install the fan housing and tighten the bolts. Torque - • Fan housing Bolts: 5.9 N1m (0.60 kgf1m, 52 in1lb) Install: Recoil Starter (see Recoil Starter Installation) • Install: Spacer [A] • Screen [B] Position three sets [C] of screen notches around the fan blades. Tighten the screen screws [D]. Torque - Screen Screws: 5.9 N1m (0.60 kgf1m, 52 in1lb) Charging System Operational Inspection • Check battery condition.
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8-12 ELECTRICAL SYSTEM Charging, Ignition System Stator Coil Resistance the connector [A]. • Disconnect Measure the stator coil resistance. • (Electric Starter Model) Connect an ohmmeter between stator pins [B]. Stator Coil Resistance (Electric Starter Model) 0.01 to 0.1 (Recoil Starter Model with Electric Clutch) Connect an ohmmeter between stator pin and engine-body. Stator Coil Resistance (Recoil Starter Model with Electric Clutch) 4.
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ELECTRICAL SYSTEM 8-13 Charging, Ignition System Regulator Resistance the KAWASAKI Hand TesterHand selector Tester switch selector to theswitch R to the R 100 100 • Set position. the test leads to the points shown on the chart and read the • Connect resistance. There are two(2) types of Regulator on FH engines as follows: (with out Charging Monitor Type …3 Blades) NOTE Resistance value may vary with individual meters.
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8-14 ELECTRICAL SYSTEM Charging, Ignition System This engine ignition is controlled by a solid state ignition assembly and requires no periodic maintenance except for the spark plugs.
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ELECTRICAL SYSTEM 8-15 Charging, Ignition System Ignition Coil Removal • Remove: Fan Housing (see Flywheel, Stator Coil Removal) Spark Plug Cap [A] Stop Switch Lead Connector [B] Bolts [C] Ignition Coil [D] Ignition Coil Installation ignition coil on crankcase so that the stop switch lead connector • Install [B] face the screen, and tighten bolt (1) first, then tighten bolt (2).
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8-16 ELECTRICAL SYSTEM Charging, Ignition System Ignition Coil Inspection the ignition coils (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 temperashould ture for this test.
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ELECTRICAL SYSTEM 8-17 Starter System Starter Motor Removal the mounting bolts [A] and pull the starter motor [B] from the • Remove engine. Starter Motor Installation the starter motor and engine mounting flanges to ensure good • Clean electrical contact and tighten the mounting bolts. Torque - Starter Motor Mounting Bolts: 15 N1m (1.5 kgf1m, 11.0 ft1lb) Starter Motor Disassembly • Remove: Through Bolts [A] Brush Plate [B] Yoke [C] Cap [D] a cloth around the Pinion assembly.
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8-18 ELECTRICAL SYSTEM Starter System Starter Motor Assembly is the reverse of disassembly. • Assembly Apply a small amount of grease to the armature shaft [A]. • the springs and holding the brush leads with suitable clips. • Press Fit the assembly [A] into the armature [B]. • Fit the brush projection [C] on the brush assembly into the notch [D] in the • yoke. • Check the cap and replace it with a new one if damaged. the brush plate and tighten the through bolts as shown.
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ELECTRICAL SYSTEM 8-19 Starter System Armature Inspection the surface of the commutator [A]. • Inspect If it is scratched or dirty, polish it with a piece of very fine emery cloth [B], and clean out the grooves. the depth of the grooves between the commutator segments. • Measure If the grooves are shallower than the specified limit, replace the armature with a new one. If the grooves are only dirty, clean them carefully. Commutator Groove Depth Limit Less than 1.0 mm (0.039 in.
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8-20 ELECTRICAL SYSTEM Starter System Pinion Clutch Inspection the pinion gear by hand. The pinion gear should turn clockwise • Turn freely. If the pinion clutch does not operate as it should, or if it makes noise, replace the pinion clutch. Recoil Starter Removal • Remove: Recoil Starter Mounting Nuts [A] Recoil Starter [B] Recoil Starter Installation • Install the recoil starter and tighten the mounting nuts. Torque - Recoil Starter Mounting Nuts: 5.9 N m (0.
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ELECTRICAL SYSTEM 8-21 Starter System • Remove: Screw [A] Washer [B] Retainer [C] Center Spring [D] Washer [E] Pawls [F] Return Springs [G] When removing the reel [A], be careful that the recoil spring [B] under the reel does not fly loose and cause injury. The spring is under great pressure. NOTE There should be no spring tension on the reel when removing it. If tension is felt, push the reel back into place and gently “wiggle” it until the reel can be easily removed.
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8-22 ELECTRICAL SYSTEM Starter System Recoil Starter Assembly Wear gloves during the recoil spring installation to avoid injury. The recoil spring must be assembled with great pressure. grease the recoil spring. • Lightly Set the recoil spring into the spring cassette. • the rope clockwise [A] on the reel, and hold the rope end [B] • Wind with tape. the spring cassette [C] on the reel so that the tongues [D] on • Install the cassette fit in the openings in the reel. grease the shaft [A].
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ELECTRICAL SYSTEM 8-23 Starter System holding the reel to keep it from unwinding, feed the end of the • While rope through the hole in the case. the rope as shown to hold it. • Clip the handle [A], and secure it with a knot [B]. • Install • Remove the clip [C] to release the rope.
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TROUBLESHOOTING 9-1 Troubleshooting Table of Contents Engine Troubleshooting Guide..........................................................................................................................................9-2 Starter Motor Troubleshooting Guide................................................................................................................................
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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. Do not unnecessarily disassemble carburetor, magneto or engine unless it has been found to be the cause of malfunctioning.
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TROUBLESHOOTING 9-3 Engine Troubleshooting Guide
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9-4 TROUBLESHOOTING Engine Troubleshooting Guide
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TROUBLESHOOTING 9-5 Engine Troubleshooting Guide
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9-6 TROUBLESHOOTING Starter Motor Troubleshooting Guide 1. 2. Disconnect spark plug caps from the spark plugs. Turn engine switch to “START” position and check condition. Engine may be cranked in this test. Do not touch any rotating parts of engine and equipment during test. CAUTION If starter does not stop by engine switch “OFF”, disconnect negative (−) lead from battery as soon as possible.