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Kawasaki FX850V Service Manual

4-stroke air-cooled v-twin gasoline engine.
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For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983
FX751V
FX801V
FX850V
4-Stroke Air-Cooled V-Twin Gasoline Engine
Service Manual
www.mymowerparts.com

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Table of Contents

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   Summary of Contents for Kawasaki FX850V

  • Page 1 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FX751V FX801V FX850V 4-Stroke Air-Cooled V-Twin Gasoline Engine Service Manual www.mymowerparts.com...
  • Page 2 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com...
  • Page 3 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 Quick Reference Guide General Information Periodic Maintenance Fuel System Cooling System Engine Top End Lubrication System Camshaft/Crankshaft Starter System Electrical System Troubleshooting 10 j This quick reference guide will assist you in locating a desired topic or pro- cedure.
  • Page 4 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com...
  • Page 5 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FX751V FX801V FX850V 4-Stroke Air-Cooled V-Twin Gasoline Engine Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Consumer Products &...
  • Page 6 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C...
  • Page 7: Emission Control Information

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated an exhaust emis- sion control system in compliance with applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board. Additionally, Kawasaki has incorpo- rated an evaporative emission control system in compliance with applicable regulations of the California Air Resources Board.
  • Page 8: How To Use This Manual

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 Foreword This manual is designed primarily for use by operations. trained mechanics in a properly equipped shop. If you want spark plug information, for exam- However, it contains enough detail and basic in- ple, go to the Periodic Maintenance Chart first.
  • Page 9 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................www.mymowerparts.com...
  • Page 10: General Information

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 1-2 GENERAL INFORMATION Before Servicing Before starting to service the engine, carefully read the applicable section to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been in- cluded wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is required for successful work.
  • Page 11 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 GENERAL INFORMATION 1-3 Before Servicing When pressing in a seal which has manufacturer’s marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole.
  • Page 12 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 1-4 GENERAL INFORMATION Model Identification FX751V, FX801V, FX850V 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.
  • Page 13 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 GENERAL INFORMATION 1-5 General Specifications Item FX751V, FX801V, FX850V Forced air-cooled, vertical shaft, OHV 4 valves, 4-stroke Type gasoline engine. Cylinder Layout 90° V-Twin Bore × Stroke 84.5 mm × 76 mm (3.33 in. × 2.99 in.) Displacement 852 cm³...
  • Page 14 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com...
  • Page 15: Table Of Contents

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... Special Tools .......................... Periodic Maintenance Procedures..................Fuel System......................... Low Idle Speed Adjustment ....................High Idle Speed Adjustment .....................
  • Page 16: Periodic Maintenance Chart

    ♦Clean and lap valve seating surface • ♦Clean combustion chambers (1): Service more frequently under dusty conditions. ♦: These items must be performed with the proper tools. See your authorized Kawasaki Engine Dealer for service, unless you have the proper equipment and mechanical proficiency. www.mymowerparts.com...
  • Page 17: Torque And Locking Agent

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 PERIODIC MAINTENANCE 2-3 Torque and Locking Agent The following tables lists the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: EO: Apply oil to the threads.
  • Page 18 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 2-4 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Breather Chamber Cover Bolts 0.60 52 in·lb Starter System Starter Motor Mounting Bolts 19.6 2.00 14.4 Electrical System Ignition Coil Bolts 0.60...
  • Page 19: Specifications

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 PERIODIC MAINTENANCE 2-5 Specifications Item Standard Fuel System Idle Speed: (1) Low Idle Speed (Carburetor idle rpm) 1 450 r/min (rpm) Low Idle Speed (Governor idle rpm) 1 550 r/min (rpm) High Idle Speed...
  • Page 20: Special Tools

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 2-6 PERIODIC MAINTENANCE Special Tools Valve Seat Cutter, 45° - 32: Valve Seat Cutter Holder Bar: 57001-1115 57001-1128 Valve Seat Cutter, 45° - 35: Valve Seat Cutter, 32° - 33: 57001-1116 57001-1199 Valve Seat Cutter, 32°...
  • Page 21: Periodic Maintenance Procedures

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 PERIODIC MAINTENANCE 2-7 Periodic Maintenance Procedures Fuel System NOTE ○ High and low idle speeds may vary depending on the equipment on which the engine is used. Refer to the equipment specification.
  • Page 22: Fuel System Cleanliness Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 2-8 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING Always keep your hands clear of the moving parts. • Loosen the locknut [A], and unscrew the high idle set screw [B] few turns. •...
  • Page 23: Air Cleaner Housing (cap And Body) Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 PERIODIC MAINTENANCE 2-9 Periodic Maintenance Procedures • Replace the secondary element [A] with a new one if dirty when primary element is checked. • Replace the secondary element every 500 hrs. CAUTION Do not wash air cleaner elements.
  • Page 24: Valve Clearance Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 2-10 PERIODIC MAINTENANCE Periodic Maintenance Procedures Valve Clearance Inspection NOTE ○ Check the valve clearance when the engine is cold (at room temperature). • Remove the rocker cover (see Cylinder Head Assembly Removal in the Engine Top End chapter).
  • Page 25: Valve Seat Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 PERIODIC MAINTENANCE 2-11 Periodic Maintenance Procedures • Holding the adjusting bolt with a spanner [A], tighten the adjusting locknut [B] to the specified torque. Torque - Valve Clearance Adjusting Locknuts: 11 N·m (1.1 kgf·m, 87 in·lb)
  • Page 26 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures If the manufacture’s instructions are not available, use the following procedure. Seat Cutter Operating Cares 1. This valve seat cutter is designed only for valve seat re- pair.
  • Page 27 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures • Coat the seat with machinist’s dye. • Fit a 45° cutter [A] to the holder and slide it into the valve guide. ○ Resurface the valve seat with a 45° cutter, removing only enough material to produce a smooth and concentric seat.
  • Page 28: Lubrication System

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures • When lapping is completed, wash all parts in solvent to remove lapping compound. Dry the parts thoroughly. • Note the position of the lapping mark on the valve face.
  • Page 29: Engine Oil Change

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Engine Oil Change • Change the oil after first 8 hours of operation. Thereafter change oil every 100 hours of operation. • Start and warm up the engine to drain the oil easily.
  • Page 30: Oil Cooler Fin Cleaning

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Replace the oil filter [A] with a new one. • Apply light film of engine oil to the seal [B]. • Install the oil filter.
  • Page 31 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-1 Fuel System Table of Contents Exploded View........................Specifications ......................... Governor Link Mechanism...................... Control Panel Assembly Removal ..................Control Panel Assembly Installation ................. Governor Arm Removal ....................Governor Arm Installation ....................
  • Page 32: Exploded View

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-2 FUEL SYSTEM Exploded View www.mymowerparts.com...
  • Page 33 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Carburetor and Inlet Pipe Mounting Bolts 0.60 52 in·lb Carburetor and Inlet Pipe Mounting Nuts 0.60 52 in·lb Air Cleaner Bracket Mounting Bolts 0.60...
  • Page 34: Specifications

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-4 FUEL SYSTEM Specifications Item Standard Carburetor Specifications: Make/Type FX751V Nikki 621266-881 FX801V Nikki 621266-871 FX850V Nikki 621266-861 Throttle Bore Diameter 26 mm (1.0 in.) Venturi Diameter 21 mm (0.83 in.) Main Jet (MJ)
  • Page 35: Governor Link Mechanism

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-5 Governor Link Mechanism Control Panel Assembly Removal • Remove: Inlet Pipe Mounting Bolt [A] and Nuts [B] Control Panel Mounting Bolts [C] Bracket [D] • Unhook the choke link rod [A] from the choke shaft lever clip end.
  • Page 36: Governor Arm Removal

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-6 FUEL SYSTEM Governor Link Mechanism Governor Arm Removal • Remove: Control Panel Assembly (see Control Panel Assembly Removal) • Unhook the throttle link rod spring [A] end loop and clear the throttle link rod lower end [B].
  • Page 37: Governor Assembly Removal

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-7 Governor Link Mechanism Governor Assembly Removal • Remove: Camshaft (see Camshaft, Tappet Removal in the Camshaft/Crankshaft chapter) Washer ( 29) [A] Snap Ring [B] Washer ( 46) [C] Sleeve [D]...
  • Page 38: Governor Shaft Installation

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-8 FUEL SYSTEM Governor Link Mechanism Governor Shaft Installation • Apply engine oil to the governor shaft. • Insert the governor shaft [A] into the crankcase cover. • Install the governor shaft plate [B] to the shaft as shown.
  • Page 39: Carburetor

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-9 Carburetor Fuel and Air Flow The main system of the carburetor consists of the main jet [A], valve seat [B], main nozzle [C], and the main air passage [D] (main air jet [E]). The main system meters fuel to the engine during moderate to heavy load conditions.
  • Page 40 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-10 FUEL SYSTEM Carburetor The pilot system includes the pilot jet [F], pilot screw [G] (Idle mixture screw), pilot air jet [H], pilot outlet [I], and the bypass holes [J]. The pilot system meters the fuel/air mixture while the engine is idling and running under a light load.
  • Page 41: Fuel Shut Off Solenoid Valve

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-11 Carburetor Fuel Shut Off Solenoid Valve To avoid after firing when stopping the engine, a solenoid actuated fuel shut off solenoid valve [A] is installed in the carburetor bowl. The valve shuts off the fuel supply to the main jets [B] simultaneously when the switch key turned to the “OFF”...
  • Page 42: Fuel System Cleanliness Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-12 FUEL SYSTEM Carburetor • Remove the float assembly [A] from the float chamber. • Remove: Pin [A] Float [B] Float Valve [C] Spacer [D] O-rings [E] • Use the rod to push the main jet “L” [A] and “R” [B] out from the bottom side of the spacer [C].
  • Page 43: Inlet Pipe Removal

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-13 Carburetor Inlet Pipe Removal • Remove: Air Cleaner (see Air Cleaner Body and Bracket Removal) Clamp [A] Breather Hose [B] Bracket Bolt [C] Inlet Pipe Mounting Bolts [D] and Nuts [E]...
  • Page 44: Carburetor Installation

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-14 FUEL SYSTEM Carburetor • Remove: Inlet Pipe (see Inlet Pipe Removal) • Close the fuel shut off valve in the equipment. • Remove the clamp [A]. • Disconnect: Fuel Tube [B] Solenoid Valve Connector [C] •...
  • Page 45: Carburetor Disassembly/assembly

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-15 Carburetor • Install the fuel tube [A] onto the pipe fully and install the clamp [B] beyond the raised rib [C]. • Apply grease (Three Bond: TB2585G) to the solenoid valve terminal.
  • Page 46 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-16 FUEL SYSTEM Carburetor • Replace the pilot screw [A] in accordance with the follow- ing procedure if necessary. ○ Remove the pilot screw plug [B] (material: Stainless steel) as follows: Punch a hole in the plug and pry it out with an awl or other suitable tool.
  • Page 47: Carburetor Cleaning

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-17 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.
  • Page 48: Carburetor Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-18 FUEL SYSTEM Carburetor Carburetor Inspection WARNING Gasoline is extremely flammable and can be explo- sive under certain. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks;...
  • Page 49: Fuel Shut Off Solenoid Valve Test

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-19 Carburetor • Inspect the tapered portion [A] of the pilot screw [B] for wear or damage. If the pilot screw is worn or damaged on the taper portion, replace it with a new one.
  • Page 50: Inlet Manifold

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-20 FUEL SYSTEM Inlet Manifold Inlet Manifold Removal • Remove: Fan Housing (see Flywheel and Stator Coil Removal in the Electrical System chapter) Carburetor (see Carburetor Removal) • Cut off the bands [A] holding the wire lead and/or harness.
  • Page 51: Inlet Manifold Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-21 Inlet Manifold Inlet Manifold Inspection • Inspect the intake manifold for cracks or porous casting. • Cracks not visible to the eye may be detected by using a metal crack detection system. (Visual color check: com- monly found at automotive parts store.)
  • Page 52: Fuel Pump, Fuel Filter

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-22 FUEL SYSTEM Fuel Pump, Fuel Filter The fuel pump cannot be disassembled. If any damage of the pump is noticed replace it with a new one. Fuel Pump Removal • Remove:...
  • Page 53: Fuel Filter Removal/installation

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-23 Fuel Pump, Fuel Filter Fuel Flow Test: WARNING Gasoline is extremely flammable and can be ex- plosive 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;...
  • Page 54: Air Cleaner

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-24 FUEL SYSTEM Air Cleaner Element Removal • While pulling up the two knobs [A], turn the cap [B] to counterclockwise [C]. • Align the arrow mark [A] and unlock mark [B] to remove the cap.
  • Page 55: Element Cleaning And Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-25 Air Cleaner • Turn the cap to the clockwise until the lock mark [A]. Element Cleaning and Inspection Air cleaner elements are not recommended to be cleaned, and each air cleaner element should be replaced with new ones.
  • Page 56: Air Cleaner Housing (cap And Body) Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-26 FUEL SYSTEM Air Cleaner • Set the air cleaner body [A] onto the lower bracket so that the air inlet duct [B] is facing upward. • Install the inlet hose [C], and tighten the clamp [D].
  • Page 57 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Cooling Fan ..........................Cooling Fan Removal ....................... Cooling Fan Installation ....................Cooling Fan Inspection ..................... Engine Shroud........................Engine Shroud Removal ....................Engine Shroud Installation ....................
  • Page 58 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 4-2 COOLING SYSTEM Exploded View www.mymowerparts.com...
  • Page 59 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Shroud Bolts (Non-locking Agent) 0.60 52 in·lb Engine Shroud Bolts (Locking Agent) 0.80 69 in·lb Cooling Fan Screen Bolts 0.60 52 in·lb...
  • Page 60 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 4-4 COOLING SYSTEM Cooling Fan Cooling Fan Removal • Refer to the Flywheel and Stator Coil Removal in the Elec- trical System chapter. Cooling Fan Installation • Refer to the Flywheel and Stator Coil Installation in the Electrical System chapter.
  • Page 61 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 COOLING SYSTEM 4-5 Engine Shroud Engine Shroud Removal • Remove: Flywheel (see Flywheel and Stator Coil Removal in the Electrical System chapter) Control Panel (see Control Panel Removal in the Fuel System chapter)
  • Page 62 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 4-6 COOLING SYSTEM Engine Shroud • Run the wire lead and harness into the groove [A] and clamp [B] of the engine shroud (#1 side). www.mymowerparts.com...
  • Page 63 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Cylinder Head......................... Compression Measurement....................Cylinder Head Assembly Removal ................... Cylinder Head Assembly Installation ................Push Rod Removal ......................
  • Page 64: Exploded View

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 5-2 ENGINE TOP END Exploded View www.mymowerparts.com...
  • Page 65 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Head Bolts (L = 50 mm) Cylinder Head Bolts (L = 60 mm) Rocker Cover Bolts 0.60 52 in·lb Valve Clearance Adjusting Locknuts 97 in·lb...
  • Page 66: Specifications

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 5-4 ENGINE TOP END Specifications Item Service Limit Cylinder Head: 440 kPa (64 psi) @ Engine Oil Temperature 50 ∼ Cylinder Compression (MIN) 60°C (122 ∼ 144°F), Cranking Speed 450 rpm/5 Seconds Cylinder Head Warp 0.03 mm (0.001 in.)
  • Page 67 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-5 Specifications Item Standard Valve Clearance: 0.05 ∼ 0.10 mm (0.0020 ∼ 0.039 in.) Inlet, Exhaust Valve Seating Surface Angle: Inlet, Exhaust 45° Valve Seating Surface Width: 1.1 ∼ 1.7 mm (0.043 ∼ 0.067 in.) Inlet 1.0 ∼...
  • Page 68: Special Tools

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 5-6 ENGINE TOP END Special Tools Piston Ring Pliers: Compression Gauge Adapter, M14 × 1.25: 57001-115 57001-1159 Compression Gauge, 20 kgf/cm²: Piston Ring Compressor Belt, 80 ∼ 91: 57001-221 57001-1320 Piston Ring Compressor Grip: 57001-1095 www.mymowerparts.com...
  • Page 69: Cylinder Head

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-7 Cylinder Head Compression Measurement • Before measuring compression, check the following. ○ Be sure the battery is fully charged. ○ Thoroughly warm up the engine so that engine oil be- tween the piston and cylinder wall will help sealing the compression as it does during normal running.
  • Page 70: Cylinder Head Assembly Removal

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 5-8 ENGINE TOP END Cylinder Head Cylinder Head Assembly Removal • Remove: Inlet Manifold (see Inlet Manifold Removal in the Fuel System chapter) Spark Plug Engine Shrouds (see Engine Shroud Removal/Installa- tion in the Cooling System chapter) •...
  • Page 71: Push Rod Removal

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-9 Cylinder Head • Set each piston at the T.D.C [A] of the compression stroke. • Put new gaskets and the cylinder head assemblies on each cylinder, then let the cylinder heads with push rods aligned under the rocker arms.
  • Page 72: Push Rod Installation

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 5-10 ENGINE TOP END Cylinder Head Push Rod Installation • Set each piston at the T.D.C of the compression stroke. • Apply engine oil to the both ends and shaft of the push rod.
  • Page 73 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-11 Cylinder Head • Remove: Rocker Arm Bracket Bolts [A] Rocker Arm Bracket [B] • Remove the cylinder head assembly. (see Cylinder Head Assembly Removal) • Support the valve head in the combustion chamber with a suitable block.
  • Page 74: Cylinder Head Cleaning

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 5-12 ENGINE TOP END Cylinder Head • Position the rocker arm [A] so that the hollow side [B] faces push rod. • Apply engine oil to the collars [A]. • For #1 cylinder, insert the collars in to the rocker arm hole so that the flatten side [B] faces PTO side.
  • Page 75: Rocker Arm Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-13 Cylinder Head Rocker Arm Inspection • Measure the diameter [A] of the rocker shafts with a mi- crometer at several points of bearing the rocker arm. If the outside diameter is less than the service limit, re- place the rocker shaft.
  • Page 76: Valves

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 5-14 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter.
  • Page 77: Valve Guide Inside Diameter

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-15 Valves Valve Guide Inside Diameter • Use a small bore gauge or a micrometer to measure the inside diameter [A] of the valve guide [B] at three positions down the guide length.
  • Page 78: Cylinder, Piston

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 5-16 ENGINE TOP END Cylinder, Piston Piston Removal • Split the crankcase (see Crankcase Cover Removal in the Camshaft/Crankshaft chapter). • Remove the camshaft (see Camshaft, Tappet Removal in the Camshaft/Crankshaft chapter).
  • Page 79: Piston Installation

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-17 Cylinder, Piston • Remove the top and second rings with piston ring pliers. Special Tool - Piston Ring Pliers: 57001-115 • If the special tool is not available, carefully spread the ring opening with your thumbs, then push up to the opposite side of the ring [A] to remove it.
  • Page 80 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 5-18 ENGINE TOP END Cylinder, Piston • When installing a piston pin snap ring, compress it only enough to install it. Do not compress the piston pin snap ring too hard. •...
  • Page 81: Piston/cylinder Seizure

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-19 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.
  • Page 82: Piston Ring And Ring Groove Wear

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 5-20 ENGINE TOP END Cylinder, Piston • Clean the piston ring grooves [A] with a broken piston ring or other suitable tools. CAUTION Be careful not to widen the ring grooves. Damaged ring grooves will require piston replacement.
  • Page 83: Piston Ring End Gap

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-21 Cylinder, Piston Piston Ring End Gap • Remove the piston rings. • Push each ring (one at a time) in the cylinder bore to a point close to the bottom of the cylinder bore.
  • Page 84: Piston Diameter

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 5-22 ENGINE TOP END Cylinder, Piston Piston Diameter • Measure the outside diameter [A] of the piston 12.5 mm (0.492 in.) [B] up from the bottom of the piston at a right angle to the direction of the piston pin hole.
  • Page 85 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 LUBRICATION SYSTEM 6-1 Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools .......................... Engine Oil, Oil Filter and Oil Cooler..................Engine Oil Level Inspection ....................Engine Oil Change......................
  • Page 86: Exploded View

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 6-2 LUBRICATION SYSTEM Exploded View www.mymowerparts.com...
  • Page 87 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 LUBRICATION SYSTEM 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil Pump Cover Plate Bolts 0.60 52 in·lb Oil Filter 11.8 1.20 104 in·lb Engine Oil Drain Plugs 0.70 34 in·lb Oil Filler Mounting Bolt 0.60...
  • Page 88: Engine Oil Flow Chart

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 6-4 LUBRICATION SYSTEM Engine Oil Flow Chart www.mymowerparts.com...
  • Page 89: Specifications

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 LUBRICATION SYSTEM 6-5 Specifications Item Standard Engine Oil: Grade SF, SG, SH, SJ or SL class Viscosity SAE40, SAE30, SAE10W-30/SAE10W-40, or SAE5W-20 Capacity: When the oil filter is not 2.1 L (2.2 US qt)
  • Page 90: Special Tools

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 6-6 LUBRICATION SYSTEM Special Tools Oil Pressure Gauge, 10 kgf/cm²: Oil Pressure Gauge Adapter, PT 1/8: 57001-164 57001-1033 www.mymowerparts.com...
  • Page 91: Engine Oil, Oil Filter And Oil Cooler

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 LUBRICATION SYSTEM 6-7 Engine Oil, Oil Filter and Oil Cooler CAUTION Engine operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure and accident.
  • Page 92: Pressurized Lubrication System

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 6-8 LUBRICATION SYSTEM Pressurized Lubrication System The engine lubrication circuit is a pressurized system consisting of a positive displacement pump which picks up oil through a filter screen from the crankcase. The oil is pumped to a replaceable oil filter cartridge, through the engine’s oil passages to lubricate internal components, and...
  • Page 93: Oil Pump, Relief Valve

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 LUBRICATION SYSTEM 6-9 Oil Pump, Relief Valve Oil Pump, Relief Valve Removal • Remove: Crankshaft (see Crankshaft Removal Camshaft/Crankshaft chapter) Bolts [A] • Take out the pump cover plate [B] , pump gear [C] and pump shaft [D] as a set.
  • Page 94: Oil Pump, Relief Valve Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 6-10 LUBRICATION SYSTEM Oil Pump, Relief Valve Oil Pump, Relief Valve Inspection • Remove the oil pump (see Oil Pump, Relief Valve Re- moval). • Visually inspect the pump gear, outer and inner rotor, and cover plate.
  • Page 95 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 LUBRICATION SYSTEM 6-11 Oil Pump, Relief Valve • Measure the outside [A] diameter of the pump shaft with a micrometer at several points. If the diameter is less than the service limit, replace the pump shaft with a new one.
  • Page 96: Oil Screen

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 6-12 LUBRICATION SYSTEM Oil Screen Oil Screen Removal • Remove the oil pump cover plate (see Oil Pump, Relief Valve Removal). • Remove the oil screen [A]. Oil Screen Installation • Clean the oil screen thoroughly whenever it is removed for any reason.
  • Page 97 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 CAMSHAFT/CRANKSHAFT 7-1 Camshaft/Crankshaft Table of Contents Exploded View........................Specifications ......................... Special Tool ..........................Crankcase ..........................Crankcase Cover Removal ....................Crankcase Cover Disassembly..................Crankcase Cover Assembly....................Crankcase Cover Installation .................... Crankcase Disassembly ....................
  • Page 98: Exploded View

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 7-2 CAMSHAFT/CRANKSHAFT Exploded View www.mymowerparts.com...
  • Page 99 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 CAMSHAFT/CRANKSHAFT 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Connecting Rod Big End Cap Bolts 20.6 2.10 15.2 Oil Passage Plugs 0.40 34 in·lb Crankcase Cover Bolts Breather Valve Mounting Screw 0.20...
  • Page 100: Specifications

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 7-4 CAMSHAFT/CRANKSHAFT Specifications Item Service Limit Camshaft, Tappet: Cam Lobe Height: Inlet 34.30 mm (1.350 in.) Exhaust 35.13 mm (1.383 in.) Camshaft Journal Diameter PTO Side 19.98 mm (0.7866 in.) Flywheel Side 19.98 mm (0.7866 in.)
  • Page 101: Special Tool

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 CAMSHAFT/CRANKSHAFT 7-5 Special Tool Bearing Driver Set: 57001-1129 www.mymowerparts.com...
  • Page 102: Crankcase

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 7-6 CAMSHAFT/CRANKSHAFT Crankcase Crankcase Cover Removal • Set the engine on a clean surface while parts are being removed. • Drain the oil (see Engine Oil Change in the Periodic Main- tenance chapter).
  • Page 103: Crankcase Cover Assembly

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 CAMSHAFT/CRANKSHAFT 7-7 Crankcase Crankcase Cover Assembly • Chip the old gasket from the mating surfaces of the crankcase and cover. • Using compressed air, blow out the oil passage in the crankcase cover.
  • Page 104: Crankcase Cover Installation

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 7-8 CAMSHAFT/CRANKSHAFT Crankcase Crankcase Cover Installation • Install the following parts into the crankcase or crankcase cover. Oil Pump and Relief Valve (see Oil Pump, Relief Valve Installation in the Lubrication System chapter)
  • Page 105: Crankcase Assembly

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 CAMSHAFT/CRANKSHAFT 7-9 Crankcase Crankcase Assembly • Remove the old gasket from the mating surfaces of the crankcase and cover. • Using compressed air, blow out the oil passage in the crankcase. •...
  • Page 106: Crankcase And Crankcase Cover Cleaning

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 7-10 CAMSHAFT/CRANKSHAFT Crankcase Crankcase and Crankcase Cover Cleaning • Remove: Oil Pump and Relief Valve (see Oil Pump, Relief Valve Removal in the Lubrication System chapter) Camshaft and Tappets (see Camshaft, Tappet Removal)
  • Page 107: Breather

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 CAMSHAFT/CRANKSHAFT 7-11 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 emis- sion control system is used to eliminate blow-by gases.
  • Page 108: Breather Valve Removal

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 7-12 CAMSHAFT/CRANKSHAFT Breather Breather Valve Removal • Remove: Inlet Manifold (see Inlet Manifold Removal in the Fuel System chapter) Flywheel (see Flywheel and Stator Coil Removal in the Electrical System chapter) Bolts [A] Breather Chamber Cover [B] •...
  • Page 109: Camshaft, Tappet

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 CAMSHAFT/CRANKSHAFT 7-13 Camshaft, Tappet Camshaft, Tappet Removal • Set the engine on a clean surface while parts are re- moved. • Drain the oil (see Engine Oil Change in the Periodic Main- tenance chapter).
  • Page 110: Camshaft Disassembly

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 7-14 CAMSHAFT/CRANKSHAFT Camshaft, Tappet Camshaft Disassembly • Remove: Governor Assembly (see Governor Assembly Removal in the Fuel System chapter) Spring [A] ○ Do not remove the ACR (automatic compression release) weight [B].
  • Page 111 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 CAMSHAFT/CRANKSHAFT 7-15 Camshaft, Tappet • Measure the inside diameter [A] of the camshaft bearing on the crankcase at several points. This bearing is not replaceable. If the inside diameter is more than the service limit, re- place the crankcase with a new one.
  • Page 112: Crankshaft, Connecting Rod

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 7-16 CAMSHAFT/CRANKSHAFT Crankshaft, Connecting Rod Connecting Rod Removal • Refer to the Piston Removal in the Engine Top End chap- ter. Connecting Rod Installation • Refer to the Piston Installation in the Engine Top End chapter.
  • Page 113: Connecting Rod Bend/twist

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 CAMSHAFT/CRANKSHAFT 7-17 Crankshaft, Connecting Rod Connecting Rod Bend/Twist • Measure the connecting rod bend. ○ Select an arbor [A] of the same diameter of the connecting rod big end, and insert the arbor through the connecting rod big end.
  • Page 114: Connecting Rod Big End Bearing/crankpin Wear

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 7-18 CAMSHAFT/CRANKSHAFT Crankshaft, Connecting Rod • Measure the crankpin width [A] with a dial caliper. If the crankpin width is greater than the service limit, re- place the crankshaft with a new one.
  • Page 115: Crankshaft Journal/wear

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 CAMSHAFT/CRANKSHAFT 7-19 Crankshaft, Connecting Rod Crankshaft Journal/Wear • Measure PTO side crankshaft journal at several points around the journal circumference. If the journal diameter is less than the service limit, re- place the crankshaft with a new one.
  • Page 116 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com...
  • Page 117 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 STARTER SYSTEM 8-1 Starter System Table of Contents Exploded View........................Specifications ......................... Special Tool ..........................Electric Starter System ......................Starter Motor Removal...................... Starter Motor Installation....................Starter Solenoid and Circuit Test ..................Starter Motor Test ......................
  • Page 118: Exploded View

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 8-2 STARTER SYSTEM Exploded View www.mymowerparts.com...
  • Page 119 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 STARTER SYSTEM 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Starter Motor Mounting Bolts 19.6 2.00 14.4 G: Apply grease. R: Replacement Parts www.mymowerparts.com...
  • Page 120: Specifications

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 8-4 STARTER SYSTEM Specifications Item Standard Service Limit Electric Starter System Starter Motor: Carbon Brush Length (with spring boss) 7.125 mm (0.2805 in.) 4.0 mm (0.16 in.) Commutator Groove Depth (approx.) 0.8 mm (0.03 in.) 0.4 mm (0.016 in.)
  • Page 121: Special Tool

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 STARTER SYSTEM 8-5 Special Tool Needle Adapter Set: 57001-1457 www.mymowerparts.com...
  • Page 122: Electric Starter System

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 8-6 STARTER SYSTEM Electric Starter System Starter Motor Removal • Disconnect the wire. • Remove the mounting bolts [A] and pull the starter motor [B] from the engine with the switch lead attached.
  • Page 123: Starter Motor Test

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 STARTER SYSTEM 8-7 Electric Starter System • Set the hand tester to the R × 1 Ω position and connect the leads as shown. Switch Terminal [A] To Ground [B] If the tester does not read close to 0 Ω, the solenoid is faulty.
  • Page 124: Starter Motor Disassembly

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 8-8 STARTER SYSTEM Electric Starter System Starter Motor Disassembly • Loosen the terminal nut [A]. • Remove the lead [B] from the starter motor to the sole- noid. • Unscrew the mounting nuts [A] and remove the solenoid assembly [B].
  • Page 125: Starter Motor Assembly

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 STARTER SYSTEM 8-9 Electric Starter System Starter Motor Assembly • Apply a small amount of grease to the armature shaft [A] as shown. • Do not reuse the snap ring [B]. Replace it with a new one.
  • Page 126: Starter Motor Brush Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 8-10 STARTER SYSTEM Electric Starter System • Using the suitable tool (for instance, socket wrench of 22 mm), expand the brushes as shown. • Install the brush assembly [A] with the suitable tool in- stalled.
  • Page 127: Brush Spring Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 STARTER SYSTEM 8-11 Electric Starter System Brush Spring Inspection • Inspection the brush springs for pitting, cracks, rusting and burrs. Replace the brush assembly if necessary. • Inspect the springs for weakened conditions and distor- tion.
  • Page 128: Yoke Assembly Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 8-12 STARTER SYSTEM Electric Starter System • Measure the armature winding resistance. ○ Set the multimeter selector switch to the R × 1 Ω position and check the resistance between each segment and all the others.
  • Page 129: Pinion Clutch Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 STARTER SYSTEM 8-13 Electric Starter System Pinion Clutch Inspection • Remove the pinion clutch. • Turn the pinion gear [A] by hand. The pinion gear should turn counterclockwise freely, but should not turn clock- wise.
  • Page 130 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com...
  • Page 131 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ELECTRICAL SYSTEM 9-1 Electrical System Table of Contents Exploded View........................Specifications ......................... Special Tool ..........................Wiring Dagram........................Precautions..........................Charging System ........................Flywheel and Stator Coil Removal..................Flywheel and Stator Coil Installation................. Charging System Operational Inspection .................
  • Page 132: Exploded View

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 9-2 ELECTRICAL SYSTEM Exploded View www.mymowerparts.com...
  • Page 133 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ELECTRICAL SYSTEM 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Ignition Coil Bolts 0.60 52 in·lb Stator Coil Screws 0.35 30 in·lb Flywheel Bolt Regulator Bolts 0.18 16 in·lb Spark Plugs G: Apply grease (Three Bond: TB2585G or equivalent).
  • Page 134: Specifications

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 9-4 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Charging System Regulated Output Voltage 14.1 V DC 15 V DC 0.01 ∼ 0.1 Ω Stator Coil Resistance – – – Unregulated Stator Output 28.4 V AC/3 000 rpm...
  • Page 135: Special Tool

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ELECTRICAL SYSTEM 9-5 Special Tool Hand Tester: 57001-1394 www.mymowerparts.com...
  • Page 136: Wiring Dagram

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 9-6 ELECTRICAL SYSTEM Wiring Dagram www.mymowerparts.com...
  • Page 137: Precautions

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ELECTRICAL SYSTEM 9-7 Precautions There are a number of important precautions that you must follow when servicing electrical systems. Learn and observe all the rules below. ○ Do not reverse the battery cable connections. This will burn out the diodes in the electrical parts.
  • Page 138: Charging System

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 9-8 ELECTRICAL SYSTEM Charging System Flywheel and Stator Coil Removal • Remove: Air Cleaner (see Air Cleaner Body and Bracket Removal in the Fuel System chapter) Oil Cooler (see Oil Cooler Removal in the Lubrication...
  • Page 139: Flywheel And Stator Coil Installation

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ELECTRICAL SYSTEM 9-9 Charging System • Hold the flywheel with a suitable tool [A], remove the fly- wheel bolt [B] and the washer. • Using a suitable flywheel puller [A], remove the flywheel [B].
  • Page 140: Charging System Operational Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 9-10 ELECTRICAL SYSTEM Charging System • Install the cooling fan [A]. • Install the plate [B] so that the slits [C] fit to the bosses [D] on the fan. • Tighten: Torque - Cooling Fan Plate Mounting Stud Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb)
  • Page 141: Stator Coil Resistance

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ELECTRICAL SYSTEM 9-11 Charging System Stator Coil Resistance • Disconnect the connector [A]. • Measure the stator coil resistance. (Electric Starter Model) ○ Connect an ohmmeter between stator pins [B]. Stator Coil Resistance 0.01 to 0.1 Ω...
  • Page 142: Regulator Resistance

    Regulator Resistance • Remove the regulator (see Regulator Removal). • Set the KAWASAKI Hand Tester selector switch to the R × 100 Ω position. • Connect the test leads to the points shown on the chart and read the resistance.
  • Page 143: Ignition System

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ELECTRICAL SYSTEM 9-13 Ignition System This engine ignition is controlled by a solid state ignition assembly and requires no periodic main- tenance except for the spark plugs. The system consists of the following:...
  • Page 144: Ignition Coil Removal

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 9-14 ELECTRICAL SYSTEM Ignition System Ignition Coil Removal • Remove: Fan Housing (see Flywheel and Stator Coil Removal) Spark Plug Cap [A] Stop Switch Lead Connector [B] Bolts [C] Ignition Coil [D] Ignition Coil Installation •...
  • Page 145: Ignition Coil Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ELECTRICAL SYSTEM 9-15 Ignition System Ignition Coil Inspection • Remove the ignition coils (see Ignition Coil Removal). • Measure the winding resistance as follows: ○ Set the hand tester to the R × 1 kΩ range.
  • Page 146 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com...
  • Page 147 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 TROUBLESHOOTING 10-1 Troubleshooting Table of Contents Engine Troubleshooting Guide ....................10-2 Starter Motor Troubleshooting Guide ..................10-6 www.mymowerparts.com...
  • Page 148 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 10-2 TROUBLESHOOTING Engine Troubleshooting Guide If the engine malfunctions, check if the way the engine is used is correct. If the engine malfunc- tions even if the engine is used correctly, systematically carry out troubleshooting starting with simple points.
  • Page 149 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 TROUBLESHOOTING 10-3 Engine Troubleshooting Guide www.mymowerparts.com...
  • Page 150 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 10-4 TROUBLESHOOTING Engine Troubleshooting Guide www.mymowerparts.com...
  • Page 151 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 TROUBLESHOOTING 10-5 Engine Troubleshooting Guide www.mymowerparts.com...
  • Page 152 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 10-6 TROUBLESHOOTING Starter Motor Troubleshooting Guide 1. Disconnect the spark plug caps from the spark plugs. 2. Turn engine switch to “start” position and check condi- tion. WARNING Engine may be cranked in this test. Do not touch any rotating parts of engine and equipment during test.
  • Page 153 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 Part No.99924-2089-01 Printed in Japan www.mymowerparts.com...

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