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. •Bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page.
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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 degree(s) Celsius revolution direct current...
EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems (EM) in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board.
This manual contains four more symbols (in maintenance. addition to WARNING and CAUTION) which will • Use proper tools and genuine Kawasaki en- help you distinguish different types of informa- gine parts. Genuine parts provided as spare tion. parts are listed in the Parts Catalog.
GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................
1-2 GENERAL INFORMATION Before Servicing Before starting to service the engine, carefully read the applicable section to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been in- cluded wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is required for successful work.
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. (13)Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips.
1-4 GENERAL INFORMATION Model Identification Electric Starter Model-FH500V Recoil Starter Model-FH500V Cylinder Number Designation: No.1 Cylinder is the left-hand cylinder viewed from the air cleaner. No.2 Cylinder is the right-hand cylinder viewed from the air cleaner.
GENERAL INFORMATION 1-5 Model Identification Electric Starter Model-FH580V Electric Starter Model-FH680V...
1-6 GENERAL INFORMATION Model Identification Heavy Duty Air Cleaner Type...
GENERAL INFORMATION 1-7 General Specifications FH451V, FH500V, FH601V, FH641V, Item FH541V, FH580V FH721V FH531V FH661V, FH680V Type Forced air-cooled, vertical shaft, OHV, 4-stroke gasoline engine. Cylinder Layout 90 V-Twin Bore × Stroke 68 mm × 68 mm 74 mm × 68 mm 75.2 mm ×...
♦ 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.
♦ 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.
M : Apply a molybdenum disulfide lubricant (grease or oil) to the threads, seated surface, or washer. O: Apply oil to the threads, seated surface, or washer. S: Tighten the fasteners following the specified sequence. SS: Apply silicone sealant. FH451V, FH500V, FH531V, FH541V, FH580V FH451V, FH500V, FH531V, FH541V, FH580V Fastener...
PERIODIC MAINTENANCE 2-5 Torque and Locking Agent FH451V, FH500V, FH531V, FH541V, FH580V Fastener Remarks Torque N·m kgf·m ft·lb Engine Top End Cylinder Head Bolts 19.0 Valve Clearance Lock Screws 0.70 61 in·lb Connecting Rod Big End Cap Bolts 0.60 52 in·lb (FH541V, FH580V) 87 in·lb...
2-6 PERIODIC MAINTENANCE Torque and Locking Agent The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.
PERIODIC MAINTENANCE 2-7 Torque and Locking Agent The following tables lists the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: L: Apply a non-permanent locking agent to the threads. M: Apply a molybdenum disulfide lubricant (grease or oil) to the threads, seated surface, or washer.
2-8 PERIODIC MAINTENANCE Torque and Locking Agent FH601V, FH641V, FH661V, FH680V, FH721V Fasteners Remarks Torque N·m kgf·m ft·lb Connecting Rod Big End Cap Bolts 87 in·lb (For M6 × P1.0 screw thread spec.) Rocker Arm Bolts Rocker Cover Mounting Bolts 0.60 52 in·lb Exhaust Pipe Flange Nuts...
High Idle Speed 3 600 r/min (rpm) Air Cleaner: Type Dual stage filtration system Pre-cleaner Foam element Second-stage cleaner Paper element FH601V, FH641V, FH451V, FH500V, FH541V, FH580V FH661V, FH680V, FH531V FH721V Type Heavy duty type Cleaner – Paper element –...
PERIODIC MAINTENANCE 2-11 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. Low Idle Speed Adjustment • Disconnect all possible external loads from the engine. •...
2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING Always keep your hands clear of the moving parts. • Move the throttle lever at a dash to the high idle position and match the lever hole position with the panel hole by inserting 6 mm dia.
If any water or dirt is found, clean the carburetor (see Carburetor Cleaning) and fuel tank. And check the fuel filter. Element Cleaning and Inspection Standard Type FH451V, FH500V, FH531V, FH541V, FH580V Models NOTE ○ In dusty areas, clean the elements more frequently than the recommended intervals.
2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Clean the paper element [A] by tapping it gently on a flat surface to remove dust. If the element is very dirty, re- place it with a new one. CAUTION Do not use compressed air to clean the paper ele- ment.
PERIODIC MAINTENANCE 2-15 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. Do not oil air cleaner elements.
2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check the cylinder head for cracks or other damage. • Cracks not visible to the eye may be detected by coating the suspected area with mixture of 25% kerosene and 75% light engine oil. •...
2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Valve Seat Repair • Follow the manufacture’s instructions for use of valve seat cutters Special Tools Inlet Valve: 57001-1116 Valve Seat Cutter 45° - 35 Valve Seat Cutter 32° - 33 57001-1199 Exhaust Valve: Valve Seat Cutter 45°...
PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Operating Procedures • Clean the seat area carefully. • Recondition the valve seats with the valve seat cutters (45°, 32°) and lap the valves. • Check the seats for good contact all the way around with machinist’s dye.
2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Coat the valve face sparingly with a fine lapping com- pound. • Use the vacuum cap tool [A], to grip the top of the valve [B]. Rotate the valve in a circular motion to lap the valve to the seat.
PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures 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. • Stop the engine. •...
2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Oil Filter Replacement • Drain the engine oil (see Oil Change). • Remove the oil filter [A] with the oil filter wrench [B] or strap wrench. Special Tool - Oil Filter Wrench: 57001-1249 ○ When unscrewing the oil filter, place a suitable container beneath the oil drip tray to receive oil from the oil filter and oil passages in the engine.
FUEL SYSTEM 3-15 Governor Link Mechanism Control Panel Assembly Removal • Remove: Air Cleaner (see Air Cleaner Body Removal) Air Cleaner Mount Bracket Bolts [A] Air Cleaner Mount Bracket [B] Ground Lead (Electric Starter Model) Control Panel Mounting Bolts [C] •...
3-16 FUEL SYSTEM Governor Link Mechanism • For FH541V, FH580V model; the governor arm is as shown in the figure. Governor Arm Installation • Install the governor arm [A] onto the governor shaft [B] temporarily. • Be sure the link spring [C] around the throttle link rod [D] is in place and that it pulls the governor arm and throttle lever [E] each other.
FUEL SYSTEM 3-17 Governor Link Mechanism Governor Assembly Installation • Fit the snap ring [A] into the groove securely. • Turn the governor plate by hand and check that the steel balls and governor plate move freely. Governor Assembly Inspection ○...
3-18 FUEL SYSTEM Carburetor Fuel and Air Flow The main system of the carburetor consists of the main jet [A], valve seat [B] main nozzle [C], and the main air passage [D] (main air jet [E]). The main system meters fuel to the engine during moderate to heavy load conditions.
FUEL SYSTEM 3-19 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.
FUEL SYSTEM 3-21 Carburetor • Using a proper standard tip screwdriver, carefully replace the main jet (A) with a new one for expected altitude. • Tighten the main jet to the specified torque (see Carbure- tor Disassembly Assembly Notes). • Install the float chamber, gasket and float bowl bolt.
• Install the inlet manifold, the new gaskets, the insulator, the carburetor, the new gasket and the inlet pipe in the sequence as shown. • For FH451V, FH500V, FH531 model; Inlet Manifold [A] Gaskets [B] Insulator [C] Carburetor [D] Gasket [E] Stud Bolt [F] •...
FUEL SYSTEM 3-23 Carburetor • For FH601V, FH641V, FH661V, FH680V, FH721V model; Inlet Manifold [A] Gaskets [B] Insulator [C] Carburetor [D] Gasket [E] • Install the air cleaner (see Air Cleaner Body Installation). • Take care not to bend the throttle link rod and choke link rods during installation.
3-24 FUEL SYSTEM Carburetor Carburetor Disassembly/Assembly-FH451V, FH500V, FH531V • Refer to the illustration for disassembly and assembly. • There are several passage plugs (Ball plugs) in the car- buretor body. Do not remove them. • Before disassembly, mark the out side of choke valve and throttle valves for assembling them.
FUEL SYSTEM 3-25 Carburetor Carburetor Disassembly/Assembly-FH541V, FH580V • Refer to the illustration for disassembly and assembly. • There are several passage plugs (Ball plugs) in the car- buretor body. Do not remove them. • Before disassembly, mark the out side of choke valve and throttle valves for assembling them.
3-26 FUEL SYSTEM Carburetor Carburetor Disassembly/Assembly-FH601V, FH641V, FH661V, FH680V, FH721V • Refer to the illustration for disassembly and assembly. • There are several passage plugs (Ball plugs) in the car- buretor body. Do not remove them. • Before disassembly, mark the out side of choke valve and throttle valves for assembling them.
FUEL SYSTEM 3-27 Carburetor Carburetor Disassembly/Assembly-FH680V and FH721V Late Models • Refer to the illustration for disassembly and assembly. • There are several passage plugs (Ball plugs) in the car- buretor body. Do not remove them. • Before disassembly, mark the out side of choke valve and throttle valves for assembling them.
3-28 FUEL SYSTEM Carburetor • Replace the pilot screw [A] with a new one if necessary in accordance with the following procedure. ○ 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.
FUEL SYSTEM 3-29 Carburetor Carburetor Cleaning WARNING Clean the carburetor in a well ventilated area, and take care that there is no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents to clean the carburetors.
3-30 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; this includes any appliance with a pilot light.
FUEL SYSTEM 3-31 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. • Check the spring condition, replace it with a new one if necessary.
• Clean the mating surfaces of the cylinders and inlet man- ifolds and fit new gaskets [A]. [B] Distance (FH451V, FH500V, FH531V): 6 mm (0.24 in.) [B] Distance (FH541V, FH580V): 0 mm (0 in.) [B] Distance (FH601V, FH641V, FH661V, FH680V, FH721V): 12 mm (0.47 in.)
FUEL SYSTEM 3-33 Inlet Manifold Inlet Manifold Inspection • Inspect the inlet 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 stores). If a crack is present in the inlet manifold, replace it with a new one.
3-34 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 Inspection • Check the vent hole [A] and the filter [B] for plugging or clogging.
FUEL SYSTEM 3-35 Air Cleaner (Standard Type) Element Removal FH451V, FH500V, FH531V, FH541V, FH580V • Pull the hooks [A] to outside and remove the air cleaner cover [B]. • Remove: Wing Bolt [A] Foam Element [B] Paper Element [C] Element Removal FH601V, FH641V, FH661V, FH680V, FH721V •...
[D]. • Unscrew the bolts [E] and remove the inlet pipe [F]. Air Cleaner Body Installation FH451V, FH500V, FH531V, FH541V, FH580V • Connect the breather tube from the crankcase to the pipe at the back of the air cleaner body.
FUEL SYSTEM 3-37 Air Cleaner (Standard Type)
3-38 FUEL SYSTEM Air Cleaner (Heavy Duty Type) Element Removal • Unhook the two retaining clamps [A] and remove the cap [B] from the air cleaner body. • Remove: Primary Element [A] Secondary Element [B] For FH541V, FH580V • Remove: Element [A] Element Installation •...
FUEL SYSTEM 3-39 Air Cleaner (Heavy Duty Type) Air Cleaner Body Removal • Remove the air cleaner elements (see Element Re- moval). • Loosen the clamps [A], and remove the inlet hose [B]. • Remove the bolt [C]. • Take out the air cleaner body [D] from the arrow side [E] in the figure.
3-40 FUEL SYSTEM Air Cleaner (Heavy Duty Type) Air Cleaner Body Installation • Install the air cleaner body bracket with the bolts to the specified torque. Torque - Air Cleaner Body Bracket Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) • Set the air cleaner body [A] onto the bracket so that the air inlet duct [B] is facing upward.
FUEL SYSTEM 3-41 Air Cleaner (Heavy Duty Type) Air Cleaner Body Clamp Bolt [A] Collar [B] Spring [C] Nut [D] 15° [E] Housing (Cap and Body) Inspection • Refer to the Housing (Cap and Body) Inspection in the Periodic Maintenance chapter.
COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Cooling Fan ..........................Cooling Fan Removal ....................... Cooling Fan Installation ....................Cooling Fan Inspection ..................... Screen Clearance Adjustment ..................
4-4 COOLING SYSTEM Cooling Fan Cooling Fan Removal • Refer to the Flywheel Removal in Electrical System chap- ter. Cooling Fan Installation • Refer to the Flywheel Installation in Electrical System chapter. Cooling Fan Inspection • Visually inspect the blades [A] in the cooling fan [B]. If they have any crack, warp or damage, replace the cool- ing fan with a new one.
ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........................Specifications ......................... Cylinder Head......................... Compression Measurement....................Cylinder Head Assembly Removal ................... 5-10 Cylinder Head Assembly Installation ................5-10 Push Rod Removal ......................5-11 Push Rod Installation ......................5-11 Push Rod Inspection......................
ENGINE TOP END 5-9 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.
5-10 ENGINE TOP END Cylinder Head Cylinder Head Assembly Removal • Remove: Air Cleaner and Carburetor (see Fuel System chapter) Muffler (see Muffler Exhaust Pipe Removal) Inlet Manifold (see Fuel System chapter) Spark Plug • Unscrew the rocker cover mounting bolts [A], and remove the cover [B] and the gasket.
ENGINE TOP END 5-11 Cylinder Head • Tighten the cylinder head bolts following the tightening sequence in the figure. Torque - Cylinder Head Bolts: 25 N·m (2.6 kgf·m, 19.0 ft·lb) CAUTION A torque wrench must be used to assure proper torque.
5-12 ENGINE TOP END Cylinder Head Push Rod Inspection • Place the push rod on V blocks as far apart as possible, and set a dial gauge on the rod at a halfway point between the blocks. Turn the rod to measure the runout. The dif- ference between the highest and the lowest dial readings is the amount of runout.
ENGINE TOP END 5-13 Valves Cylinder Head Cleaning and Inspection • Refer to the Cylinder Head Cleaning and Inspection in the Periodic Maintenance chapter. Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment •...
5-14 ENGINE TOP END 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. If the measured valve diameter is greater than the service limit, replace the cylinder head with a new one.
ENGINE TOP END 5-15 Cylinder, Piston Piston Removal • Split the crankcase (see Camshaft/Crankshaft chapter). • Remove the camshaft (see Camshaft/Crankshaft chap- ter). • Turn the crankshaft to expose the connecting rod cap bolts [A]. • Remove the bolts and take off the connecting rod caps [B].
Install the top and second rings as shown in the figure. The rings should turn freely in the grooves. Piston Head [A] Top Ring for FH451V, 500V, 531V, 541V, 580V [B] Second Ring for FH451V, 500V, 531V, 541V, 580V [C] Top Ring for , FH601V, 641V, 661V, 680V, 721V [D] Second Ring for FH601V, 641V, 661V, 680V, 721V [E] •...
ENGINE TOP END 5-17 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. • Fit a new piston pin snap ring into the side of the piston so that the ring opening [A] does not coincide with the notch [B] on the edge of the piston pin hole.
Apply a thin layer of engine oil to the thread [D] and seat- ing surface [E] of the cap bolts. • Tighten the cap bolts. Torque - [FH451V, 500V, 531V] Connecting Rod Big End Cap Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) [FH541V, 580V] Connecting Rod Big End Cap Bolts: 9.8 N·m (1.0...
[A] as shown in the figure. If the piston ring/groove clearance is greater than the ser- vice limit, replace the piston with a new one. Piston Ring/Groove Clearance Service Limit FH601V, FH641V, FH451V, FH500V, FH541V, FH661V, FH680V, FH531V FH580V FH721V ←...
If the end gap of any ring is greater than the service limit, replace the entire set of rings with new ones. Piston Ring End Gap Service Limit FH601V, FH641V, FH451V, FH500V, FH541V, FH661V, FH680V, FH531V FH580V FH721V 0.70 mm (0.028 in.)
If the measured outside diameter is less than the service limit, replace the piston with a new one. Piston Diameter Model Service Limit FH451V, FH500V, FH531V 67.79 mm (2.669 in.) FH541V, FH580V 73.79 mm (2.905 in.) FH601V, FH641V, FH661V, FH680V, 74.99 mm (2.952 in.)
Cylinder, Piston Cylinder Inside Diameter Service Model Item Standard Limit 67.98 ∼ 68.00 mm Standard 68.10 mm FH451V, (2.676 ∼ 2.677 in.) Cylinder (2.681 in.) FH500V, 68.48 ∼ 68.50 mm FH531V 0.5 mm Oversize 68.60 mm (2.696 ∼ 2.697 in.) Cylinder (2.701 in.)
ENGINE TOP END 5-23 Cylinder, Piston Change to a honing stone for finishing, the final inside di- ameter should be as shown in the table. • Be sure to use correct finishing stone and the stone should not be worn. •...
5-24 ENGINE TOP END Muffler/Exhaust Pipe Installation Muffler/Exhaust Pipe Removal Early Models; • Loosen the clamp nut [A]. • Remove the bolt [B] on the muffler bracket and take off the muffler. Late Models; • Loosen the clamp nut [A]. •...
ENGINE TOP END 5-25 Muffler/Exhaust Pipe Installation Inspection • Inspect the exhaust pipe or muffler for dents, cracks, rust and holes. If the exhaust pipe or muffler is damaged, replace the exhaust pipe or the muffler with a new one for the best performance and minimum noise.
LUBRICATION SYSTEM 6-1 Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Engine Oil Flow Chart......................Specifications ......................... Engine Oil, Oil Filter, and Oil Cooler..................Oil Level Inspection......................Oil Change ........................Oil Filter Removal ......................Oil Filter Installation ......................Oil Filter Replacement ......................
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. Before starting the engine for the first time, add oil: The engine is shipped dry.
6-8 LUBRICATION SYSTEM Engine Oil, Oil Filter, and Oil Cooler Oil Cooler Removal (FH721V) • Remove the oil filter (see Oil Filter Removal). • Unscrew the mounting joint [A] and remove the oil cooler [B]. • Check the O-ring [C] in the groove of the oil cooler for damage.
Apply silicone sealant to the threads of the pressure switch and tighten it, or tighten the oil passage plug. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Pressure Switch: 9.8 N·m (1.0 kgf·m, 87 in·lb) Oil Passage Plug: 3.9 N·m (0.40 kgf·m, 35 in·lb) If the measured oil pressure is below the specification, inspect the oil pump and the relief valve.
6-10 LUBRICATION SYSTEM Pressurized Lubrication System Oil Pressure Switch Inspection When the oil pressure falls below 98 kPa (14.2 psi), the oil pressure switch activates the oil warning lamp to alert the operator or lubricating problem. • To check the oil warning system, insert the switch key into the engine switch at the “OFF”...
6-12 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, the outer and inner rotor, and the cover plate. If there is any damage or uneven wear, replace them with new ones.
LUBRICATION SYSTEM 6-13 Oil Pump, Relief Valve • Before FH500-A50136, FH531-A07510 model, the pump housing is as shown in the figure. • 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.
6-14 LUBRICATION SYSTEM Oil Pump, Relief Valve If cleaning does not solve the problem, replace the relief valve parts with new ones. If necessary, put the ball in position and lightly tap the ball with a suitable tool to form a perfect seat. •...
LUBRICATION SYSTEM 6-15 Oil Screen Oil Screen Removal • Remove the crankcase cover (see Camshaft/Crankcase chapter). • Unscrew the mounting bolts [A] and remove the oil pump parts assembly. • Remove the oil screen [B]. • Before FH500-A50136, FH531-A07510 model, the oil screen is as shown in the figure.
6-16 LUBRICATION SYSTEM Oil Screen Cleaning and Inspection • Clean the oil screen with high-flash point solvent and re- move any particles on it. WARNING Clean the screen in a well ventilated area, and take care that there is no spark or flame anywhere near the working area.
CAMSHAFT/CRANKSHAFT 7-5 Crankcase Crankcase Cover Removal • Set the engine on a clean surface while parts are being removed. • 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) •...
Replace the crankcase with a new one if the inside diameter is greater than the service limit. Crankshaft Journal Bearing Inside Diameter Model Service Limit FH451V, 500V, 531V 35.15 mm (1.384 in.) FH541V, 580V 35.15 mm (1.384 in.) FH601V, 641V, 661V, 680V, 721V 40.15 mm (1.581 in.)
7-8 CAMSHAFT/CRANKSHAFT Breather The function of the breather is to create a vacuum in the crankcase which prevents oil from being forced out of the engine through the piston rings, oil seals or gaskets. A sealed-type crankcase emis- sion 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.
CAMSHAFT/CRANKSHAFT 7-9 Breather [Heavy Duty Air Cleaner Type for FH541V, FH580V]...
7-10 CAMSHAFT/CRANKSHAFT Breather [Heavy Duty Air Cleaner Type for FH601V, FH641V,FH680V, FH721V]...
CAMSHAFT/CRANKSHAFT 7-11 Breather Breather Element Removal - FH451V, 500V, 531V, 541V, 580V • Remove the bolts [A] and the breather chamber cover [B]. • Remove the element [A]. • Check to see that the plate [B] is in place under the ele- ment [A].
7-12 CAMSHAFT/CRANKSHAFT Camshaft, Tappet Camshaft, Tappet Removal • Set the engine on a clean surface while parts are re- moved. • 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) Inlet Manifold (see Fuel System chapter) Crankcase Cover (see Crankcase Cover Removal)
If the cam height is less than the service limit for either lobe, replace the camshaft with a new one. Cam Lobe Height Model Service Limit FH451V, 500V, 531V IN. 29.131 mm (1.1469 in.) EX. 29.131 mm (1.1469 in.) FH541V, 580V IN. 29.131 mm (1.1469 in.) EX.
7-14 CAMSHAFT/CRANKSHAFT Camshaft, Tappet • Measure both camshaft journals at several points around the journal circumference. If the journal diameter is less than the service limit, re- place the camshaft with a new one. PTO Side Camshaft Journal Diameter Service Limit: 15.985 mm (0.6293 in.) Flywheel Side Camshaft Journal Diameter Service Limit: 15.985 mm (0.6293 in.) •...
CAMSHAFT/CRANKSHAFT 7-15 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 • Set the engine on a clean surface while parts are re- moved.
If the measurement is less than the service limit, replace the connecting rod with a new one. Connecting Rod Big End Width Model Service Limit FH451V, 500V, 531V 18.80 mm (0.74 in.) FH541V, 580V 18.80 mm (0.74 in.) FH601V, 641V, 661V, 680V, 721V...
If the crankpin width is greater than the service limit, re- place the crankshaft with a new one. Crankpin Width Model Service Limit FH451V, 500V, 531V 39.50 mm (1.56 in.) FH541V, 580V 39.50 mm (1.56 in.) FH601V, 641V, 661V, 680V, 721V 43.1 mm (1.697 in.)
If the journal diameter is less than the service limit, re- place the crankshaft with a new one. PTO Side Crankshaft Journal Diameter [A] Model Service Limit FH451V, 500V, 531V 34.90 mm (1.374 in.) FH541V, 580V 34.90 mm (1.374 in.) FH601V, 641V, 661V, 680V, 721V 39.896 mm (1.571 in.)
STARTER SYSTEM 8-1 Starter System Table of Contents Exploded View........................Specifications ......................... Starter System........................Starter Motor Removal...................... Starter Motor Installation....................Starter Motor Disassembly....................Starter Motor Assembly ....................Starter Motor Brush Inspection ..................Brush Spring Inspection....................Armature Inspection......................Yoke Assembly Inspection ....................Pinion Clutch Inspection ....................
8-4 STARTER SYSTEM Specifications Standard Item Service Limit FH451V, 500V, FH601V, 641V, 531V, 541V, 580V 661V, 680V, 721V Electric Starter System Starter Motor: Carbon Brush Length (with spring boss) 12.7 mm (0.500 in.) 6.4 mm (0.250 in.) Commutator Groove Depth (approx.) 2.0 mm (0.078 in.)
STARTER SYSTEM 8-5 Starter System Starter Motor Removal • Remove the mounting bolts [A] and pull the starter motor [B] from the engine. Starter Motor Installation • Clean the starter motor and engine mounting flanges to ensure good electrical contact and tighten the mounting bolts.
8-6 STARTER SYSTEM Starter System Starter Motor Assembly • Assemble the starter motor in the reverse of disassembly. • Apply a small amount of grease [A] to the armature shaft. • Do not reuse the snap ring [B]. Replace it with a new one. •...
STARTER SYSTEM 8-7 Starter System • Measure the depth of the grooves between the commu- tator segments. If the grooves are shallower than the specified limit, re- place the armature with a new one. If the grooves are only dirty, clean them carefully. Commutator Groove Depth Limit 0.9 mm (0.035 in.) Bad [A]...
8-8 STARTER SYSTEM Starter System • Test the armature winding for shorts. ○ Place the armature on a growler [A]. ○ Hold a thin metal strip (e.g., hack saw blade) on top of the armature. ○ Turn on the growler and rotate the armature one complete turn.
STARTER SYSTEM 8-9 Starter System Recoil Starter Disassembly • Remove the recoil starter (see Recoil Starter Removal). • Pull the handle [A] out 30 cm (1 ft), and clamp the rope [B] with the clip [C] so it can not wind back onto the reel [D].
8-10 STARTER SYSTEM Starter System If necessary, remove the recoil spring [A] as follows: ○ Place the cassette [B] facing down in a suitable container. ○ Tap the cassette [B] to remove the recoil spring. Recoil Starter Assembly WARNING Wear gloves during the recoil spring installation to avoid injury.
STARTER SYSTEM 8-11 Starter System • Install: Retainer [A] Washer [B] Screw [C] Torque - Recoil Starter Retainer Screw: 7.8 N·m (0.80 kgf·m, 69 in·lb) • Turn the reel two turns counterclockwise to preload the recoil spring. • While holding the reel to keep it from unwinding, feed the end of the rope through the hole in the case.
9-4 ELECTRICAL SYSTEM Specifications Standard Item Service Limit FH451V, 500V, 531V, FH601V, 641V, 541V, 580V 661V, 680V, 721V Charging System Regulated Output Voltage 14.1 V DC 15 V DC Alternator Stator Coil Resistance in the text – – – Unregulated Stator Output 28.4 V AC/3 000 rpm...
ELECTRICAL SYSTEM 9-9 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. ○...
9-10 ELECTRICAL SYSTEM Charging System Flywheel, Stator Coil Removal • Remove: Recoil Starter (see Recoil Starter Removal) • Loosen the fan housing bolts [A] and remove the fan housing [B]. • Remove: Ignition Coils (see Ignition Coil Removal) Stud Bolts [A] •...
ELECTRICAL SYSTEM 9-11 Charging System ○ Remove: Ignition Coil (see Ignition Coil Removal) Stud Bolts [A] ○ Hold the flywheel with a suitable tool, remove the flywheel bolt and the washer. • Using a suitable flywheel puller [A], remove the flywheel [B].
9-12 ELECTRICAL SYSTEM Charging System • Install the fan [A] so that two positioning bosses [B] fit around flywheel ignition magnet [C]. • Install the plate [D] so that the notch [E] inserts into the slot in the flywheel. • Install the screen [A] so that the projections [B] fit into the recess [C] of the fan.
ELECTRICAL SYSTEM 9-13 Charging System ○ Install: Spacer [A] Screen [B] ○ Position three sets [C] of screen notches around the fan blades. ○ Tighten the screen bolts [D] Torque - Screen Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) Charging System Operational Inspection •...
9-14 ELECTRICAL SYSTEM 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 (Electric Starter Model) 0.01 to 0.1 Ω (Recoil Starter Model with Electric Clutch) ○...
ELECTRICAL SYSTEM 9-15 Charging System Regulator Resistance • 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. ○ There are two (2) types of Regulator on FH engines as follows: (Without Charging Monitor Type …3 Blades)
9-16 ELECTRICAL SYSTEM Ignition System This engine ignition is controlled by a solid state ignition assembly and requires no periodic main- tenance except for the spark plugs. The system consists of the following: Inductive Ignition Assemblies Permanent Magnet Flywheel Spark Plugs Stop Switch Ignition Theory of Operation Mounted to the periphery of a flywheel are a pair of magnetic poles (south leading in clockwise...
ELECTRICAL SYSTEM 9-17 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 • Install the ignition coil on the crankcase so that the stop switch lead connector [B] face the screen, and tighten the bolt (1) first, then tighten the bolts (2).
CAUTION Use only Tester 57001-1394 with new battery at room temperature for this test. A tester other than the Kawasaki Hand Tester should show different readings. If a megger or a meter with a large capacity battery is used, the ignition coil will be damaged.
TROUBLESHOOTING 10-1 Troubleshooting Table of Contents Engine Troubleshooting Guide ....................10-2 Starter Motor Troubleshooting Guide ..................10-6...
10-2 TROUBLESHOOTING Engine Troubleshooting Guide If the engine malfunctions, check if the way the engine is used is correct. If the engine malfunc- tions even if the engine is used correctly, systematically carry out troubleshooting starting with simple points. This chart describes typical troubleshooting procedures. Do not unnecessarily disassemble the carburetor, the magneto or the engine unless it has been found to be the cause of malfunctioning.
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.
Part No.99924-2045-08 Printed in Japan...