Download  Print this page

Kawasaki FH451V Service Manual

4-stroke air-cooled v-twin gasoline engine.
Hide thumbs

Advertisement

FH451V, FH500V, FH531V
FH541V, FH580V, FH601V
FH641V, FH661V, FH680V
FH721V
4-Stroke Air-Cooled V-Twin Gasoline Engine
Service Manual

Advertisement

Table of Contents

   Related Manuals for Kawasaki FH451V

   Summary of Contents for Kawasaki FH451V

  • Page 1 FH451V, FH500V, FH531V FH541V, FH580V, FH601V FH641V, FH661V, FH680V FH721V 4-Stroke Air-Cooled V-Twin Gasoline Engine Service Manual...
  • Page 3: General Information

    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.
  • Page 5 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 Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
  • Page 6 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...
  • Page 7: Emission Control Information

    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.
  • Page 8: How To Use This Manual

    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.
  • Page 9 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................
  • Page 10: Before Servicing

    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 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.
  • Page 12: Model Identification

    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.
  • Page 13 GENERAL INFORMATION 1-5 Model Identification Electric Starter Model-FH580V Electric Starter Model-FH680V...
  • Page 14 1-6 GENERAL INFORMATION Model Identification Heavy Duty Air Cleaner Type...
  • Page 15: General Specifications

    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 ×...
  • Page 17: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... Special Tools .......................... 2-10 Periodic Maintenance Procedures..................2-11 Fuel System......................... 2-11 Low Idle Speed Adjustment ....................2-11 High Idle Speed Adjustment ..................... 2-11 Fuel System Cleanliness Inspection .................
  • Page 18: Periodic Maintenance Chart

    ♦ 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.
  • Page 19 ♦ 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.
  • Page 20: Torque And Locking Agent

    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...
  • Page 21 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...
  • Page 22 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.
  • Page 23 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.
  • Page 24 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...
  • Page 25: Specifications

    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 –...
  • Page 26: Special Tools

    2-10 PERIODIC MAINTENANCE Special Tools Valve Seat Cutter, 45° - 35: Valve Seat Cutter, 32° - 33: 57001-1116 57001-1199 Valve Seat Cutter, 32° - 30: Oil Filter Wrench: 57001-1120 57001-1249 Valve Seat Cutter Holder Bar: Valve Seat Cutter Holder, 6: 57001-1128 57001-1360...
  • Page 27: Periodic Maintenance Procedures

    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. •...
  • Page 28 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.
  • Page 29: Fuel System Cleanliness Inspection

    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.
  • Page 30 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.
  • Page 31: Housing (cap And Body) Inspection

    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.
  • Page 32: Valve Clearance Inspection

    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. •...
  • Page 33: Valve Clearance Adjustment

    If the valve seating pattern is not correct, repair the seat. Valve Seating Surface Width (STD) [FH451V, FH500V, FH531V, FH541V, FH580V] Inlet, Exhaust 0.6 ∼ 0.9 mm (0.024 ∼ 0.035 in.) [FH601V, FH641V, FH661V, FH680V, FH721V] 0.8 ∼...
  • Page 34: Valve Seat Repair

    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°...
  • Page 35 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.
  • Page 36: Lubrication System

    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.
  • Page 37: Oil Change

    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. •...
  • Page 38: Oil Filter Replacement

    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.
  • Page 39 Main Jet Replacement ...................... 3-20 Fuel System Cleanliness Inspection ................. 3-21 Carburetor Removal......................3-21 Carburetor Installation....................... 3-22 Carburetor Disassembly/Assembly-FH451V, FH500V, FH531V........3-24 Carburetor Disassembly/Assembly-FH541V, FH580V ............. 3-25 Carburetor Disassembly/Assembly-FH601V, FH641V, FH661V, FH680V, FH721V ..3-26 Carburetor Disassembly/Assembly-FH680V and FH721V Late Models......3-27 Carburetor Cleaning......................
  • Page 40: Exploded View

    3-2 FUEL SYSTEM Exploded View [FH451V, FH500V, FH531V]...
  • Page 41 FUEL SYSTEM 3-3 Exploded View [FH451V, FH500V, FH531V] 1. Pilot Screw 2. Pilot Air Jet 3. Main Air Jet 4. Main Jet 5. Pilot Jet 6. Solenoid Valve 7. Out Vent Tube (Before 2003/5 Product model) T1: 0.7 N·m (0.07 kgf·m, 6 in·lb) T2: 1.0 N·m (0.10 kgf·m, 9 in·lb)
  • Page 42 3-4 FUEL SYSTEM Exploded View [FH541V, FH580V]...
  • Page 43 FUEL SYSTEM 3-5 Exploded View [FH541V, FH580V] 1. Pilot Screw 2. Main Jet 3. Solenoid Valve T1: 0.7 N·m (0.07 kgf·m, 6 in·lb) T2: 2.3 N·m (0.23 kgf·m, 20 in·lb) T3: 4.5 N·m (0.46 kgf·m, 40 in·lb) T4: 3.4 N·m (0.35 kgf·m, 30 in·lb) T5: 5.9 N·m (0.60 kgf·m, 52 in·lb) L: Apply non-permanent locking agent.
  • Page 44 3-6 FUEL SYSTEM Exploded View [Heavy Duty Air Cleaner Type]...
  • Page 45 FUEL SYSTEM 3-7 Exploded View [Heavy Duty Air Cleaner Type] 1. Pilot Screw 2. Main Jet 3. Solenoid Valve T1: 0.7 N·m (0.07 kgf·m, 6 in·lb) T2: 2.3 N·m (0.23 kgf·m, 20 in·lb) T3: 4.5 N·m (0.46 kgf·m, 40 in·lb) T4: 5.9 N·m (0.60 kgf·m, 52 in·lb) T5: 9.8 N·m (1.0 kgf·m, 87 in·lb) L: Apply non-permanent locking agent.
  • Page 46 3-8 FUEL SYSTEM Exploded View [FH601V, FH641V, FH661V, FH680V, FH721V]...
  • Page 47 FUEL SYSTEM 3-9 Exploded View [FH601V, FH641V, FH661V, FH680V, FH721V] 1. Pilot Screw 2. Pilot Air Jet 3. Main Air Jet 4. Main Jet 5. Pilot Jet 6. Solenoid Valve 7. Out Vent Tube (Before 2003/5 Product model) T1: 1.0 N·m (0.10 kgf·m, 9 in·lb) T2: 3.9 N·m (0.40 kgf·m, 35 in·lb) T3: 2.0 N·m (0.20 kgf·m, 18 in·lb) T4: 19 N·m (1.9 kgf·m, 14 ft·lb)
  • Page 48 3-10 FUEL SYSTEM Exploded View [Heavy Duty Air Cleaner Type]...
  • Page 49 FUEL SYSTEM 3-11 Exploded View [Heavy Duty Air Cleaner Type] 1. Main Jet 2. Pilot Screw 3. Solenoid Valve R: Replacement Parts T1: 1.0 N·m (0.10 kgf·m, 9 in·lb) T2: 3.9 N·m (0.40 kgf·m, 35 in·lb) T3: 2.0 N·m (0.20 kgf·m, 18 in·lb) T4: 2.5 N·m (0.25 kgf·m, 22 in·lb) T5: 6.9 N·m (0.70 kgf·m, 61 in·lb) T6: 9.8 N·m (1.0 kgf·m, 87 in·lb)
  • Page 50 3-12 FUEL SYSTEM Exploded View...
  • Page 51 FUEL SYSTEM 3-13 Exploded View [FH451V, FH500V, FH531V] T1: 5.9 N·m (0.60 kgf·m , 52 in·lb) T2: 2.0 N·m (0.20 kgf·m , 17 in·lb) T3: 7.8 N·m (0.80 kgf·m , 69 in·lb) [FH541V, FH580V] T1: 5.9 N·m (0.60 kgf·m , 52 in·lb) T2: 2.0 N·m (0.20 kgf·m , 17 in·lb)
  • Page 52: Specifications

    3-14 FUEL SYSTEM Specifications Standard FH601V, FH641V, Item FH451V, FH531V FH541V FH580V FH661V, FH680V, FH500V FH721V Carburetor Specifications: Make/Type MIKUNI B24T1 ← Walbro LMF ← Nikki 621266 Throttle Bore Diameter 24 mm (0.94 in.) ← ← ← 26 mm (1.02 in.) Venturi Diameter 16 mm (0.63 in.) 18 mm...
  • Page 53: Governor Link Mechanism

    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] •...
  • Page 54: Governor Arm Installation

    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.
  • Page 55: Governor Assembly Installation

    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 ○...
  • Page 56: Carburetor

    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.
  • Page 57 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.
  • Page 58: Fuel Shut Off Solenoid Valve (electric Starter Model)

    The main jet numbers are stamped on the ends of the main jets. High Altitude Main Jet Main Jet No. FH601V FH641V FH680V and FH451V Altitude FH531V FH541V FH580V FH680V FH721V Late FH500V FH661V...
  • Page 59: Fuel System Cleanliness Inspection

    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.
  • Page 60: Carburetor Installation

    • 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] •...
  • Page 61 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.
  • Page 62: Carburetor Disassembly/assembly-fh451v, Fh500v, Fh531v

    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.
  • Page 63: Carburetor Disassembly/assembly-fh541v, Fh580v

    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.
  • Page 64: Carburetor Disassembly/assembly-fh601v, Fh641v, Fh661v, Fh680v, Fh721v

    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.
  • Page 65: Carburetor Disassembly/assembly-fh680v And Fh721v Late Models

    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.
  • Page 66 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.
  • Page 67: Carburetor Cleaning

    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.
  • Page 68: Carburetor Inspection

    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.
  • Page 69: Fuel Shut Off Solenoid Valve Test (electric Starter Model)

    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.
  • Page 70: Inlet Manifold

    • 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.)
  • Page 71: Inlet Manifold Inspection

    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.
  • Page 72: Fuel Pump, Fuel Filter

    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.
  • Page 73: Air Cleaner (standard Type)

    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 •...
  • Page 74: Air Cleaner Body Installation

    [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.
  • Page 75 FUEL SYSTEM 3-37 Air Cleaner (Standard Type)
  • Page 76: Air Cleaner (heavy Duty 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 •...
  • Page 77: Air Cleaner Body Removal

    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.
  • Page 78: Air Cleaner Body Installation

    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.
  • Page 79: Housing (cap And Body) Inspection

    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.
  • Page 81 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 ..................
  • Page 82 4-2 COOLING SYSTEM Exploded View...
  • Page 83: Cooling System

    COOLING SYSTEM 4-3 Exploded View [FH451V, FH500V, FH531V] T1: 3.9 N·m (0.40 kgf·m, 35 in·lb) T2: 5.9 N·m (0.60 kgf·m, 52 in·lb) T3: 17 N·m (1.7 kgf·m, 12.0 ft·lb) T4: 56 N·m (5.7 kgf·m, 41 ft·lb) T5: 7.8 N·m (0.80 kgf·m, 69 in·lb) [FH541V, FH580V] T1: 3.9 N·m (0.40 kgf·m, 35 in·lb)
  • Page 84: Cooling Fan

    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.
  • Page 85 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......................
  • Page 86: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 87 ENGINE TOP END 5-3 Exploded View [FH451V, FH500V, FH531V] T1: 5.9 N·m (0.60 kgf·m, 52 in·lb) T2: 6.9 N·m (0.70 kgf·m, 61 in·lb) T3: 25 N·m (2.6 kgf·m, 19.5 ft·lb) T4: 28 N·m (2.8 kgf·m, 20 ft·lb) T5: 22 N·m (2.2 kgf·m, 16 ft·lb) [FH541V, FH580V] T1: 9.8 N·m (1.0 kgf·m, 87 in·lb)
  • Page 88 5-4 ENGINE TOP END Exploded View...
  • Page 89 ENGINE TOP END 5-5 Exploded View [FH451V, FH500V, FH531V] T2: 15 N·m (1.5 kgf·m, 11.0 ft·lb) [FH541V, FH580V] T2: 15 N·m (1.5 kgf·m, 11.0 ft·lb) [FH601V, FH641V, FH661V, FH680V, FH721V] T2: 15 N·m (1.5 kgf·m, 11.0 ft·lb) 1. Muffler Comp for Late Models.
  • Page 90: Specifications

    5-6 ENGINE TOP END Specifications Service Limit Item FH451V, FH500V, FH531V FH541V, FH580V Cylinder Head Cylinder Compression (MIN) [390 kPa (57 psi)] (MIN) ← Cylinder Head Warp 0.05 mm (0.002 in.) ← Valves Valve Head Thickness Inlet, Exhaust 0.35 mm (0.014 in.) ←...
  • Page 91 ENGINE TOP END 5-7 Specifications Service Limit Item FH601V, FH641V, FH661V, FH680V, FH721V Cylinder Head Cylinder Compression (MIN) [390 kPa (57 psi)] (MIN) Cylinder Head Warp 0.05 mm (0.002 in.) Valves Valve Head Thickness Inlet, Exhaust 0.35 mm (0.014 in.) Valve Stem Runout Inlet, Exhaust 0.05 mm (0.002 in.)
  • Page 92 5-8 ENGINE TOP END Specifications Special Tools - Piston Ring Pliers: 57001-115 Compression Gauge, 20 kgf/cm²: 57001-221 Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Belt, 67 ∼ 79: 57001-1097 Compression Gauge Adapter, M14 × 1.25: 57001-1159 Valve Seat Cutter Holder Bar: 57001-1128 Valve Seat Cutter Holder, 6: 57001-1360 Valve Seat Cutter, 45°...
  • Page 93: Compression Measurement

    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.
  • Page 94: Cylinder Head Assembly Removal

    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.
  • Page 95: Push Rod Removal

    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.
  • Page 96: Push Rod Inspection

    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.
  • Page 97: Valves

    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 •...
  • Page 98: Valve Guide Inside Diameter

    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.
  • Page 99: Cylinder, Piston

    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].
  • Page 100: Piston Installation

    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] •...
  • Page 101 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.
  • Page 102: Piston/cylinder Seizure

    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...
  • Page 103: Piston Cleaning

    [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 ←...
  • Page 104: Piston Ring End Gap

    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.)
  • Page 105: Piston Diameter

    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.)
  • Page 106: Cylinder Boring And Honing

    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.)
  • Page 107 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. •...
  • Page 108: Muffler/exhaust Pipe Installation

    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]. •...
  • Page 109: Inspection

    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.
  • Page 111 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 ......................
  • Page 112: Exploded View

    6-2 LUBRICATION SYSTEM Exploded View...
  • Page 113 T8: 5.9 N·m (0.60 kgf·m, 52 in·lb) T9: 44 N·m (4.5 kgf·m, 33 ft·lb) A: FH721V B: Before FH500V-A50316, FH531V-A07510 Model C: FH451V, FH500V, FH531V, FH451V, FH580V Model D: FH601V, FH641V, FH661V, FH680V, FH721V Model O: Apply engine oil. SS: Apply silicone sealant.
  • Page 114: Engine Oil Flow Chart

    6-4 LUBRICATION SYSTEM Engine Oil Flow Chart FH451V, FH500V, FH531V, FH601V, FH641V, FH661V, FH680V, FH721V...
  • Page 115: Engine Oil Flow Chart

    LUBRICATION SYSTEM 6-5 Engine Oil Flow Chart FH541V FH580V FH601V, FH641V, FH661V, FH680V, FH721V (On and after 2003/5 product model)
  • Page 116: Specifications

    Pump shaft outside diameter 10.923 mm (0.4300 in.) Pump shaft bearing inside 11.072 mm (0.4359 in.) diameter Relief valve spring free length 19.50 mm (0.77 in.) Special Tool - Oil Filter Wrench: 57001-1249 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 117: Engine Oil, Oil Filter, And Oil Cooler

    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.
  • Page 118: Oil Cooler Removal (fh721v)

    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.
  • Page 119: Pressurized Lubrication System

    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.
  • Page 120: Oil Pressure Switch Inspection

    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”...
  • Page 121: Oil Pump, Relief Valve

    LUBRICATION SYSTEM 6-11 Oil Pump, Relief Valve Oil Pump, Relief Valve Removal • Remove the crankcase cover (see Camshaft/Crankshaft chapter). • Unscrew the mounting bolts and remove the oil pump parts assembly (pump gear, pump cover plate, pump shaft, pins and rotors). •...
  • Page 122: Oil Pump, Relief Valve Inspection

    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.
  • Page 123 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.
  • Page 124 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. •...
  • Page 125: Oil Screen

    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.
  • Page 126: Cleaning And Inspection

    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.
  • Page 127 Crankcase Cover Removal ....................Crankcase Cover Installation .................... Inspection.......................... Cleaning..........................Breather..........................Breather Element Removal - FH451V, 500V, 531V, 541V, 580V ........7-11 Breather Element Installation - FH451V, 500V, 531V, 541V, 580V ........7-11 Breather Valve Inspection - FH601V, 641V, 661V, 680V, 721V ........
  • Page 128: Exploded View

    7-2 CAMSHAFT/CRANKSHAFT Exploded View...
  • Page 129 T3: See Engine Top End chapter. G: Apply grease. O: Apply engine oil. S: Follow the specific tightening sequence. SS: Apply silicone sealant. A: FH451V, FH500V, FH531V, FH541V, FH580V Model B: FH601V, FH641V, FH661V, FH680V, FH721V Model C: Applicable Model only 1. Screw 2. Plate...
  • Page 130: Specifications

    (1.571 in.) Crankcase PTO Shaft Bearing Inside 35.15 mm ← 40.15 mm Diameter Crankcase Cover (1.384 in.) (1.581 in.) Crankshaft Journal Bearing 35.15 mm ← 40.15 mm Inside Diameter Crankcase (1.384 in.) (1.581 in.) Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 131: Crankcase

    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) •...
  • Page 132: Inspection

    PTO Shaft 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.)
  • Page 133: Cleaning

    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.)
  • Page 134: Breather

    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.
  • Page 135 CAMSHAFT/CRANKSHAFT 7-9 Breather [Heavy Duty Air Cleaner Type for FH541V, FH580V]...
  • Page 136 7-10 CAMSHAFT/CRANKSHAFT Breather [Heavy Duty Air Cleaner Type for FH601V, FH641V,FH680V, FH721V]...
  • Page 137: Breather Element Removal - Fh451v, 500v, 531v, 541v, 580v

    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].
  • Page 138: Camshaft, Tappet

    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)
  • Page 139: Camshaft Disassembly

    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.
  • Page 140 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.) •...
  • Page 141: Crankshaft, Connecting Rod

    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.
  • Page 142: Connecting Rod Bend/twist

    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...
  • Page 143: Connecting Rod Big End Bearing/crankpin Wear

    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.)
  • Page 144: Crankshaft Main Journal/wear

    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.)
  • Page 145 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 ....................
  • Page 146: Exploded View

    8-2 STARTER SYSTEM Exploded View...
  • Page 147 STARTER SYSTEM 8-3 Exploded View [FH451V, FH500V, FH531V] T1: 3.9 N·m (0.40 kgf·m, 35 in·lb) T2: 5.9 N·m (0.60 kgf·m, 52 in·lb) T3: 7.8 N·m (0.80 kgf·m, 69 in·lb) T4: 17 N·m (1.7 kgf·m, 12 ft·lb) [FH541V, FH580V] T1: 3.9 N·m (0.40 kgf·m, 35 in·lb) T2: 5.9 N·m (0.60 kgf·m, 52 in·lb)
  • Page 148: Specifications

    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.)
  • Page 149: Starter System

    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.
  • Page 150: Starter Motor Assembly

    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. •...
  • Page 151 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]...
  • Page 152: Yoke Assembly Inspection

    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.
  • Page 153: Recoil Starter Disassembly

    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].
  • Page 154: Recoil Starter Assembly

    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.
  • Page 155 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.
  • Page 157 ELECTRICAL SYSTEM 9-1 Electrical System Table of Contents Exploded View........................Specifications ......................... Wiring Diagram [FH451V, FH500V, FH531V, FH541V, FH580V] ........... Wiring Diagram [FH451V, FH500V, FH531V]................. Wiring Diagram [FH601V, FH641V, FH661V, FH680V, FH721V] ........... Precautions..........................Charging System ........................9-10 Flywheel, Stator Coil Removal..................
  • Page 158: Exploded View

    9-2 ELECTRICAL SYSTEM Exploded View...
  • Page 159 ELECTRICAL SYSTEM 9-3 Exploded View [FH451V, FH500V, FH531V] T1: 3.9 N·m (0.40 kgf·m, 35 in·lb) T2: 5.9 N·m (0.60 kgf·m, 52 in·lb) T3: 7.8 N·m (0.80 kgf·m, 69 in·lb) T4: 22 N·m (2.2 kgf·m, 16 ft·lb) T5: 56 N·m (5.7 kgf·m, 41 ft·lb) [FH541V, FH580V] T1: 3.9 N·m (0.40 kgf·m, 35 in·lb)
  • Page 160: Specifications

    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...
  • Page 161: Wiring Diagram [fh451v, Fh500v, Fh531v, Fh541v, Fh580v]

    ELECTRICAL SYSTEM 9-5 Wiring Diagram [FH451V, FH500V, FH531V, FH541V, FH580V] Electric Starter Model...
  • Page 162: Wiring Diagram [fh451v, Fh500v, Fh531v]

    9-6 ELECTRICAL SYSTEM Wiring Diagram [FH451V, FH500V, FH531V] Recoil Starter (with Charging Coil) Model...
  • Page 163 ELECTRICAL SYSTEM 9-7 Wiring Diagram [FH451V, FH500V, FH531V] Recoil Starter Model...
  • Page 164: Wiring Diagram [fh601v, Fh641v, Fh661v, Fh680v, Fh721v]

    9-8 ELECTRICAL SYSTEM Wiring Diagram [FH601V, FH641V, FH661V, FH680V, FH721V] Electric Starter Model...
  • Page 165: Precautions

    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. ○...
  • Page 166: Charging System

    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] •...
  • Page 167: Flywheel, Stator Coil Installation

    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].
  • Page 168 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.
  • Page 169: Charging System Operational Inspection

    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 •...
  • Page 170: Stator Coil Resistance

    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) ○...
  • Page 171: Regulator Resistance

    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)
  • Page 172: Ignition System

    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...
  • Page 173: Ignition Coil Removal

    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).
  • Page 174: Ignition Coil Inspection

    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.
  • Page 175 TROUBLESHOOTING 10-1 Troubleshooting Table of Contents Engine Troubleshooting Guide ....................10-2 Starter Motor Troubleshooting Guide ..................10-6...
  • Page 176 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.
  • Page 177 TROUBLESHOOTING 10-3 Engine Troubleshooting Guide...
  • Page 178 10-4 TROUBLESHOOTING Engine Troubleshooting Guide...
  • Page 179 TROUBLESHOOTING 10-5 Engine Troubleshooting Guide...
  • Page 180 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 181 Part No.99924-2045-08 Printed in Japan...

This manual is also suitable for:

Fh500vFh531vFh580vFh601vFh641vFh661v ... Show all

Comments to this Manuals

Symbols: 0
Latest comments: