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Kawasaki FJ151V Service Manual

4-stroke air-cooled gasoline engine.
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FJ151V
FJ180V
4-Stroke Air-Cooled Gasoline Engine
Service Manual

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Table of Contents

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   Summary of Contents for Kawasaki FJ151V

  • Page 1 FJ151V FJ180V 4-Stroke Air-Cooled 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 information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2002 Kawasaki Heavy Industries, Ltd. Fourth Edition (1) : Jul. 20, 2006 (K)
  • 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

    • venient operation. Use proper tools and genuine Kawasaki en- • gine parts. Genuine parts provided as spare Indicates a procedural step or work to be parts are listed in the Parts Catalog.
  • Page 9 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................
  • 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 (12)Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips. Before a shaft passes through a seal, apply a little oil, preferably high-temperature grease on the lips to reduce rubber to metal friction.
  • Page 12: Model Identification

    1-4 GENERAL INFORMATION Model Identification FJ180V (Recoil Starter Model) FJ180V (Electric Starter Model)
  • Page 13: General Specifications

    Not specified (Priming Start Model) High Idle Speed 3 300 rpm (r/min) (Choke Start Model) 3 200 rpm (r/min) (Priming Start Model) 2 950 rpm (r/min) (FJ151V Model) Ignition System Flywheel magneto with CDI Per Canada and U.S.A. requirements Starting System...
  • Page 14: Unit Conversion Table

    1-6 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 N·m ×...
  • Page 15: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... Special Tools .......................... Periodic Maintenance Procedures..................Fuel System......................... Idle Speed Adjustment (Choke Start Model)..............Idle Speed Adjustment (Priming Start Model)..............Fuel System Cleanliness Inspection ................. Fuel Filter Inspection......................
  • Page 16: Periodic Maintenance Chart

    Clean and lap valve seating surface • Clean combustion chamber (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 17: Torque And Locking Agent

    PERIODIC MAINTENANCE 2-3 Torque and Locking Agent The following tables list the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the "Remarks" column mean: L : Apply a non-permanent locking agent. O : Apply engine oil.
  • Page 18 2-4 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Starter Motor Mounting Bolts 0.70 61 in·lb Fuel Tank Cover Bolts 0.70 61 in·lb Electrical System Flywheel Bolt Spark Plug Kill Switch Bolt 0.15 13 in·lb The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts.
  • Page 19: Specifications

    1 550 r/min (rpm) Priming Start Model Not specified High Idle Speed: Choke Start Model 3 300 r/min (rpm) Priming Start Model 3 200 r/min (rpm) FJ151V Model 2 950 r/min (rpm) Air Cleaner: Type Dual stage filtration system Cleaner: First Foam element...
  • Page 20: Special Tools

    2-6 PERIODIC MAINTENANCE Special Tools Valve Seat Cutter, 45° - 27.5: Valve Seat Cutter Holder Bar: 57001-1114 57001-1128 Valve Seat Cutter, 32° - 25: Valve Seat Cutter Holder, 6: 57001-1118 57001-1360 Valve Seat Cutter, 32° - 28: 57001-1119...
  • Page 21: Periodic Maintenance Procedures

    High Idle Speed 3 300 r/min (rpm) 2 950 r/min (rpm) (FJ151V Model) • Remove the 6 mm (0.24 in.) diameter pin or bolt from the control panel. Low Idle Speed Adjustment •...
  • Page 22: Idle Speed Adjustment (priming Start Model)

    2-8 PERIODIC MAINTENANCE Periodic Maintenance Procedures Choke Adjustment • Stop the engine. • Move the throttle lever [A] at a dash to the high idle po- sition, align bend part of throttle lever with hole of control panel [B] and insert the 6 mm (0.24 in.) diameter pin or bolt [C] through hole.
  • Page 23: Fuel Filter Inspection

    PERIODIC MAINTENANCE 2-9 Periodic Maintenance Procedures Choke Start Model • Place a suitable container [B] under the bolt [A] of the carburetor. • Loosen the bolt to drain the carburetor and check to see if water or dirt has accumulated in the carburetor. •...
  • Page 24: Air Cleaner Element Removal

    2-10 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Visually inspect the fuel filter [B] of the fuel tap [A]. If the filter is clear with no signs of dirt or other contami- nation, the replacement of the filter is not necessary. If the filter is dark or looks dirty, replace it with a new one.
  • Page 25: Air Cleaner Element Installation

    PERIODIC MAINTENANCE 2-11 Periodic Maintenance Procedures Air Cleaner Element Installation • Install: Foam Element Paper Element • Install the hollow [A] of the air cleaner case to fit the pro- jection [B] of the air cleaner body. • Move the holders [A]. Air Cleaner Element Cleaning and Inspection NOTE ○...
  • Page 26: Air Cleaner Housing (case And Body) Inspection

    2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Cleaner Housing (Case and Body) Inspection • Clean the housing with detergent and water and dry it thoroughly. • Check the housing for deformation or other damage. Seal the housing well and permit only filtered air to reach the carburetor.
  • Page 27: Valve Clearance Inspection

    PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Valve Clearance Inspection NOTE ○ Valve clearance must be checked when the engine is cold (at room temperature). • Remove the rocker cover (see Cylinder Head Assembly Removal in the Engine Top End chapter). •...
  • Page 28: Valve Seat Inspection

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Valve Seat Inspection • Remove the valve (see Valve Mechanism Removal/Instal- lation in the Engine Top End chapter). • Inspect the valve seats for damage. If the seats are warped or distorted beyond recondition- ing, replace the cylinder head with a new one.
  • Page 29 PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures If the manufacturer’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. Do not use the valve seat cutter for other purposes. 2.
  • Page 30 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Coat the seat with machinist’s dye. • Fit a 45° seat 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 31: Lubrication System

    PERIODIC MAINTENANCE 2-17 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. The lapping mark should appear on or near the center of the valve face.
  • Page 32: Electrical System

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the oil filler cap and pour in the specified type and amount of oil. Engine Oil Type: SF, SG, SH or SJ Class Viscosity: SAE30, SAE10W-30 Capacity: 0.65 L (0.69 US qt) Electrical System Spark Plug Cleaning and Inspection •...
  • Page 33 FUEL SYSTEM 3-1 Fuel System Table of Contents Exploded View........Carburetor Installation....3-17 Specifications ........Carburetor Disassembly/Assem- Governor Link Mechanism (Choke bly ..........3-18 Start Model) ........Carburetor Cleaning..... 3-21 Control Panel Assembly Removal Carburetor Inspection ....3-22 Control Panel Assembly Priming Pump ........
  • Page 34: Exploded View

    3-2 FUEL SYSTEM Exploded View...
  • Page 35 FUEL SYSTEM 3-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Governor Arm Clamp Nut 0.80 69 in·lb Fuel Tank Cover Bolts 0.70 61 in·lb Tank Drain Bolt 0.70 61 in·lb 4. Modified Model 5. Priming Start Model 6. Choke Start Model R: Replacement Parts...
  • Page 36 3-4 FUEL SYSTEM Exploded View...
  • Page 37 48 in·lb Float Chamber Mounting Bolt 0.45 39 in·lb (Choke Start Model) Float Chamber Mounting Bolt 0.61 53 in·lb (Modified Model) 8. Modified Model 9. Choke Start Model 10. FJ151V Model L: Apply a non-permanent locking agent. R: Replacement Parts...
  • Page 38: Specifications

    1 550 r/min (rpm) (Choke Start Model) Not specified (Priming Start Model) High 3 300 r/min (rpm) (Choke Start Model) 3 200 r/min (rpm) (Priming Start Model) 2 950 r/min (rpm) (FJ151V Model) Air Cleaner Type Dual stage filtration system Pre-cleaner...
  • Page 39: Governor Link Mechanism (choke Start Model)

    FUEL SYSTEM 3-7 Governor Link Mechanism (Choke Start Model) Control Panel Assembly Removal • Remove: Air Cleaner Elements (see Air Cleaner Element Re- moval) Recoil Starter (see Recoil Starter Removal in the Starter System chapter) Fuel Tank (see Fuel Tank Removal) Control Panel Mounting Bolts [A] •...
  • Page 40: Governor Link Mechanism (priming Start Model)

    3-8 FUEL SYSTEM Governor Link Mechanism (Priming Start Model) Control Panel Assembly Removal • Remove: Air Cleaner Elements (see Air Cleaner Element Re- moval) Recoil Starter (see Recoil Starter Removal in the Starter System chapter) Fuel Tank (see Fuel Tank Removal) Control Panel Mounting Bolts [A] •...
  • Page 41: Governor Link Mechanism

    FUEL SYSTEM 3-9 Governor Link Mechanism 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 the throttle lever [E] toward each other.
  • Page 42: Governor Assembly Installation

    3-10 FUEL SYSTEM Governor Link Mechanism • When removing the governor gear assembly [A] for re- placing, use two screw drivers [B] of an appropriate size. CAUTION Protect the gasket-mount surface of the crankcase cover when removing the governor assembly with the screw drivers.
  • Page 43: Governor Shaft Installation

    FUEL SYSTEM 3-11 Governor Link Mechanism Governor Shaft Installation • Apply engine oil to the governor shaft. • Install: Washer [A] Governor Shaft [B] Snap Pin [C] • Check that the governor shaft moves freely in its operating range.
  • Page 44: Carburetor

    3-12 FUEL SYSTEM Carburetor Fuel and Air Flow (Choke Start Model) The main system of the carburetor consists of the main jet [A], the main nozzle [B], and the main air passage [C] (main air jet [D]). The main system meters fuel to the en- gine during moderate to high load conditions.
  • Page 45: Fuel And Air Flow (priming Start Model)

    FUEL SYSTEM 3-13 Carburetor Fuel and Air Flow (Priming Start Model) The main system of the carburetor consists of the main jet [A], the main nozzle [B], and the main air passage [C] (main air jet [D]). The main system meters fuel to the en- gine during moderate to high load conditions.
  • Page 46: High Altitude Operation

    3-14 FUEL SYSTEM Carburetor High Altitude Operation At high altitude, the standard carburetor air-fuel mixture will be excessively rich. Performance will decrease, and fuel consumption will increase. High altitude performance can be improved by installing a smaller diameter main jet in the carburetor and correct idle speed.
  • Page 47 FUEL SYSTEM 3-15 Carburetor • Install the primer pipe [A] and the drain screw as shown in the figure. 90° ∼ 100° [B] • For Choke Start model; note the following. • Place the engine on a level surface. • Drain the fuel in the carburetor completely by unscrewing the bolt [A] at the bottom of the float chamber.
  • Page 48: Fuel System Cleanliness Inspection

    3-16 FUEL SYSTEM Carburetor • Install the pipe [A] of the float chamber as shown in the figure. 90° ∼ 100° [B] • For Modified model; note the following. • Using a properly sized blade screw driver, carefully re- place the main jet [A] with a new one for expected altitude. •...
  • Page 49: Carburetor Removal

    FUEL SYSTEM 3-17 Carburetor Carburetor Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the engine switch stop position. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks, this includes any appliance with a pilot light.
  • Page 50: Carburetor Disassembly/assembly

    3-18 FUEL SYSTEM Carburetor Carburetor Disassembly/Assembly • Refer to the illustration shown for disassembly and as- sembly. • There are several passage plugs (ball plugs) in the car- buretor body. Do not remove them. • Before disassembly, mark the outside of throttle valve for assembling them.
  • Page 51 FUEL SYSTEM 3-19 Carburetor • For Choke Start model 1. Throttle Valve Screw 2. Throttle Valve 3. Throttle Shaft 4. Seal 5. Screw 6. Spring 7. Limiter 8. Pilot Screw 9. Spring 10. Choke Valve 11. Choke Shaft 12. Seal 13.
  • Page 52 3-20 FUEL SYSTEM Carburetor • For Priming Start model 1. Throttle Valve Screw 2. Throttle Valve 3. Throttle Shaft 4. Seal 5. Screw 6. Spring 7. Limiter 8. Pilot Screw 9. Spring 10. Main Nozzle 11. Main Jet 12. Float 13.
  • Page 53: Carburetor Cleaning

    FUEL SYSTEM 3-21 Carburetor Carburetor Cleaning WARNING Clean the carburetor in a well ventilated area, and take care that there is no sparks or flame anywhere near the working area, this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents to clean the carburetor.
  • Page 54: Carburetor Inspection

    3-22 FUEL SYSTEM Carburetor Carburetor Inspection WARNING Gasoline is extremely flammable and can be explo- sive under certain. Turn the engine switch stop position. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light.
  • Page 55 FUEL SYSTEM 3-23 Carburetor • Inspect the float valve for excessive wear or damage. The tip should be smooth, without any grooves, scratches, or tears. The rod at the other end of the needle should move smoothly when pushed in and released. Good [A] Bad [B] If either the needle or the seat is worn or damaged, re-...
  • Page 56: Priming Pump

    3-24 FUEL SYSTEM Priming Pump Priming Pump Removal • Remove the tube [A] from the priming pump. • Remove the nut [B] and washer [C]. • Remove the priming pump from the inlet manifold. • Inspect the priming pump for damages. If the priming pump is damaged, replace it with a new one.
  • Page 57: Inlet Manifold (choke Start Model)

    FUEL SYSTEM 3-25 Inlet Manifold (Choke Start Model) Inlet Manifold Removal • Unscrew the inlet manifold mounting bolts [A]. • Remove the breather pipe [B] from the inlet manifold. Inlet Manifold Installation • Replace the O-ring [A] with a new one. •...
  • Page 58: Inlet Manifold (priming Start Model)

    3-26 FUEL SYSTEM Inlet Manifold (Priming Start Model) Inlet Manifold Removal • Unscrew the inlet manifold mounting bolts [A]. • Remove the breather pipe [B] from the inlet manifold. Inlet Manifold Installation • Replace the O-ring [A] with a new one. •...
  • Page 59: Inlet Manifold

    FUEL SYSTEM 3-27 Inlet Manifold Inlet Manifold Inspection • Inspect the inlet manifold for cracks. • 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). If a crack is present in the inlet manifold, replace it with a new one.
  • Page 60: Fuel Tank

    3-28 FUEL SYSTEM Fuel Tank Fuel Tank Removal • Remove: Air Cleaner Elements (see Air Cleaner Element Re- moval) Recoil Starter (see Recoil Starter Removal in the Starter System chapter) Oil Gauge Fuel Tank Cover Bolts [A] • For Modified model; note the following. •...
  • Page 61: Fuel Tank Cleaning

    FUEL SYSTEM 3-29 Fuel Tank Fuel Tank Cleaning WARNING Clean the fuel tank in a well ventilated area, and take care that there is no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvent to clean the tank.
  • Page 62: Fuel Filter

    3-30 FUEL SYSTEM Fuel Filter Fuel Filter Inspection • Refer to the Fuel Filter Inspection in the Peri- odic Maintenance chapter.
  • Page 63: Air Cleaner

    FUEL SYSTEM 3-31 Air Cleaner Air Cleaner Element Removal • Refer to the Air Cleaner Element Removal in the Periodic Maintenance chapter. Air Cleaner Element Installation • Refer to the Air Cleaner Element Installation in the Peri- odic Maintenance chapter. Air Cleaner Element Cleaning and Inspection •...
  • Page 65 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Cooling Fan ..........................Cooling Fan Removal ....................... Cooling Fan Installation ....................Cooling Fan Inspection .....................
  • Page 66 4-2 COOLING SYSTEM Exploded View...
  • Page 67 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Flywheel Bolt Fuel Tank Cover Bolts 0.70 61 in·lb 3. Modified Model...
  • Page 68: Cooling System

    4-4 COOLING SYSTEM Cooling Fan Cooling Fan Removal • Refer to the Flywheel Removal in the Electrical System chapter. Cooling Fan Installation • Refer to the Flywheel Installation in the Electrical System chapter. Cooling Fan Inspection • Visually inspect the blades [A] in the cooling fan [B]. If they are any cracks, warps or damage, replace the cool- ing fan.
  • Page 69 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 ......................Push Rod Installation ......................Push Rod Inspection......................5-10 Valve Mechanism Removal/Installation ................
  • Page 70: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 71 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Head Bolts (7T) Cylinder Head Bolts (7N) Cylinder Head Bolts (9N) Valve Clearance Lock Screws 0.70 61 in·lb Connecting Rod Big End Cap Bolts 0.60 52 in·lb Rocker Arm Bolts Spark Plug Rocker Cover Mounting Bolts...
  • Page 72: Specifications

    5-4 ENGINE TOP END Specifications Item Service Limit Cylinder Head Cylinder Compression 196 kPa (2.0 kgf/cm², 28.4 psi) (MIN) Cylinder Head Warp 0.03 mm (0.001 in.) Valves Valve Head Thickness: Exhaust 0.36 mm (0.014 in.) Inlet 0.35 mm (0.014 in.) Valve Stem Runout: Exhaust 0.05 mm (0.002 in.)
  • Page 73 ENGINE TOP END 5-5 Specifications Item Standard Valves Valve Clearance: 0.10 ∼ 0.15 mm (0.004 ∼ 0.006 in.) Exhaust 0.10 ∼ 0.15 mm (0.004 ∼ 0.006 in.) Inlet Valve Seating Surface Angle: Exhaust 45° Inlet 45° Valve Seating Surface Width: 0.6 ∼...
  • Page 74: Special Tools

    5-6 ENGINE TOP END Special Tools Piston Ring Compression Belt, 55 ∼ 67: Compression Gauge: 57001-221 57001-1096 Piston Ring Compression: Compression Gauge Adapter M14 × 1.25: 57001-1095 57001-1159...
  • Page 75: Cylinder Head

    ENGINE TOP END 5-7 Cylinder Head Compression Measurement • Before measuring compression, do the following. ○ Thoroughly warm up the engine so that engine oil be- tween the piston and cylinder wall will help seal compres- sion as it does during normal running. ○...
  • Page 76: Cylinder Head Assembly Removal

    5-8 ENGINE TOP END Cylinder Head Cylinder Head Assembly Removal • Remove: Air Cleaner Elements (see Air Cleaner Element in the Fuel System chapter) Recoil Starter (see Recoil Starter Removal in the Starter System chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) Muffler (see Muffler Removal) Fan Housing (see Flywheel Removal in the Electrical...
  • Page 77: Push Rod Removal

    ENGINE TOP END 5-9 Cylinder Head • Tighten the cylinder head bolts following the tightening sequence as shown in the figure. Torque - Cylinder Head Bolts: 7T: 22 N·m (2.2 kgf·m, 16 ft·lb) 7N: 25 N·m (2.5 kgf·m, 18 ft·lb) 9N: 26 N·m (2.6 kgf·m, 19 ft·lb) CAUTION A torque wrench must be used to assure proper...
  • Page 78: Push Rod Inspection

    5-10 ENGINE TOP END Cylinder Head Push Rod Inspection • Place the push rod in V blocks that are as far apart as possible, and set a dial gauge [A] on the rod at the halfway point between the blocks. Turn the rod to measure the runout.
  • Page 79: Cleaning And Inspection

    ENGINE TOP END 5-11 Cylinder Head • Apply engine oil to the valve stem. • Install the valve. • Check to see that the valve moves smoothly up and down in the guide. • Install the spring and the valve retainer. •...
  • Page 80: Valves

    5-12 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. Valve Seat Inspection • Refer to the Valve Seat Inspection in the Periodic Mainte- nance chapter.
  • Page 81: Valve Guide Inside Diameter

    ENGINE TOP END 5-13 Valves Valve Guide Inside Diameter • Use a small bore gauge or a micrometer to measure the inside diameter [A] of the valve guides [B] at three posi- tions down the guide length. If the measurement is more than the service limit, replace the cylinder head with a new one.
  • Page 82: Cylinder, Piston

    5-14 ENGINE TOP END Cylinder, Piston Piston Removal • Remove: Air Cleaner Elements (see Air Cleaner Element in the Fuel System chapter) Recoil Starter (see Recoil Starter Removal in the Starter System chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) Flywheel (see Flywheel Removal in the Electrical Sys- tem chapter)
  • Page 83: Piston Installation

    ENGINE TOP END 5-15 Cylinder, Piston • Carefully spread the ring opening with your thumbs then push up to the opposite side of the ring [A] to remove it. • Remove the 3-piece oil ring with your thumbs in the same manner.
  • Page 84 5-16 ENGINE TOP END Cylinder, Piston • Install the snap ring [A] in the piston [B] as shown in the figure. CAUTION Do not reuse the snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall.
  • Page 85: Piston Cleaning

    ENGINE TOP END 5-17 Cylinder, Piston Piston Cleaning • Remove the piston and piston rings (see Piston Re- moval). CAUTION Never clean the piston head assembled. Carbon particles will fall between the piston and cylinder, and damage the piston and cylinder. •...
  • Page 86: Piston Ring End Gap

    5-18 ENGINE TOP END Cylinder, Piston • Measure the piston ring thickness [A]. ○ Use a micrometer to measure the ring thickness at several points around the rings. If any of the measurement is less than the service limit, replace the entire set of rings with new ones. Piston Ring Thickness Service Limit: 1.40 mm (0.055 in.)
  • Page 87: Piston Diameter

    ENGINE TOP END 5-19 Cylinder, Piston • Measure the inside diameter [A] of the connecting rod small end at several points. Use a dial bore gauge. If the inside diameter is greater than the service limit, re- place the connecting rod with a new one. Connecting Rod Small End Inside Diameter Service Limit: 16.06 mm (0.632 in.) Piston Diameter...
  • Page 88: Muffler

    5-20 ENGINE TOP END Muffler Muffler Removal • Remove: Muffler Cover Bolt [C] Muffler Cover Nuts [A] Muffler Cover [B] Muffler • Remove the gasket. • Do not use unnecessary force on the muffler when remov- ing the muffler assembly, or they could become damaged or distorted.
  • Page 89 LUBRICATION SYSTEM 6-1 Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Engine Oil ..........................Oil Level Inspection......................Oil Change ........................Lubrication System ......................... Oil Pump..........................Oil Pump Removal ......................Oil Pump Installation ......................Oil Pump Inspection......................
  • Page 90: Exploded View

    6-2 LUBRICATION SYSTEM Exploded View...
  • Page 91 LUBRICATION SYSTEM 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil Drain Plug Oil Filter Cover Bolt 0.70 61 in·lb O: Apply engine oil. R: Replacement Parts...
  • Page 92: Engine Oil Flow Chart

    6-4 LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 93: Specifications

    LUBRICATION SYSTEM 6-5 Specifications Item Standard Engine Oil Type SF, SG, SH or SJ class Viscosity SAE30, SAE10W-30 Capacity 0.65 L (0.69 US qt) Level Operating range (grid area) on dipstick Item Service Limit Oil Pump Inner and Outer Rotor Clearance 0.14 mm (0.006 in.) Outer Rotor Outside Diameter 22.940 mm (0.9031 in.)
  • Page 94: Engine Oil

    6-6 LUBRICATION SYSTEM Engine Oil CAUTION Engine operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure and accident. Before starting the engine for the first time, add oil: The engine is shipped dry. Preoil the engine to force all air from the internal oil passages.
  • Page 95 LUBRICATION SYSTEM 6-7 Lubrication System The oil pump on the camshaft top discharges the oil. The oil passes the crankcase oil passage, the discharge hole on the crankcase flywheel side, and the camshaft gear side edge. Finally, the oil mist lubricates the connecting rod big end, the small end, the crankshaft and other internal components.
  • Page 96: Oil Pump

    6-8 LUBRICATION SYSTEM Oil Pump Oil Pump Removal • Remove: Air Cleaner Elements (see Air Cleaner Element Removal in the Fuel System chapter) Recoil Starter (see Recoil Stater Removal in the Starter System chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) Flywheel (see Flywheel Removal in the Electrical Sys- tem chapter)
  • Page 97 LUBRICATION SYSTEM 6-9 Oil Pump • Measure the outside diameter [A] of the outer rotor with a micrometer at several points. If the rotor diameter is less than the service limit, replace both the inner and outer rotor with new ones. Outer Rotor Outside Diameter Service Limit: 22.940 mm (0.9031 in.) •...
  • Page 99 CAMSHAFT/CRANKSHAFT 7-1 Camshaft/Crankshaft Table of Contents Exploded View........................Specifications ......................... Crankcase ..........................Crankcase Cover Removal ....................Crankcase Cover Installation .................... Inspection.......................... Cleaning..........................Breather..........................Breather Chamber Cover Removal .................. Breather Chamber Cover Installation ................Breather Valve Inspection ....................Camshaft, Tappet ........................7-10 Camshaft, Tappet Removal....................
  • Page 100: Exploded View

    7-2 CAMSHAFT/CRANKSHAFT Exploded View...
  • Page 101 CAMSHAFT/CRANKSHAFT 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Crankcase Cover Bolts 0.90 78 in·lb Connecting Rod Big End Cap Bolts 0.60 52 in·lb Valve Clearance Lock Screws 0.70 61 in·lb Rocker Arm Bolts HG: Apply high-temperature grease. O: Apply engine oil. R: Replacement Parts S: Follow the specified tightening sequence.
  • Page 102: Specifications

    7-4 CAMSHAFT/CRANKSHAFT Specifications Item Service Limit Camshaft, Tappet Cam Lobe Height: Exhaust 22.060 mm (0.8685 in.) Inlet 22.060 mm (0.8685 in.) Camshaft Journal Diameter: PTO Side 7.77 mm (0.3059 in.) Flywheel Side 13.927 mm (0.5483 in.) Camshaft Hole Inside Diameter: Crankcase Cover 11.060 mm (0.4354 in.) Crankshaft, Connecting Rod...
  • Page 103: Crankcase

    CAMSHAFT/CRANKSHAFT 7-5 Crankcase Crankcase Cover Removal • Drain the oil (see Oil Change in the Lubrication System chapter). • Remove: Air Cleaner Elements (see Air Cleaner Element Removal in the Fuel System chapter) Recoil Starter (see Recoil Starter Removal in the Starter System chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System chapter)
  • Page 104: Inspection

    7-6 CAMSHAFT/CRANKSHAFT Crankcase • Be sure to replace any oil seal with a new one. ○ Install the oil seal so that the marks [A] face out. ○ Thoroughly pack high-temperature grease [B] into the space between the seal lip [C] and the dust lip [D]. Press in the new oil seal using a press or suitable tools until it is flush with flange surface [E].
  • Page 105: Cleaning

    CAMSHAFT/CRANKSHAFT 7-7 Crankcase • Measure the inside diameter [A] of the crankshaft journal metal on the crankcase at several points. Replace the crankcase with a new one if the inside diameter is greater than the service limit. Crankshaft Journal Metal Inside Diameter Service Limit: 27.98 mm (1.102 in.) Cleaning •...
  • Page 106: Breather

    7-8 CAMSHAFT/CRANKSHAFT Breather The function of the breather is to create a negative pressure in the crankcase which prevents oil from being forced out of the engine through the piston rings, oil seals or gaskets. Valve controls direction of air flow caused by piston movement so that air flow from inside to outside can pass reed valve but not from outside to inside.
  • Page 107: Breather Chamber Cover Removal

    CAMSHAFT/CRANKSHAFT 7-9 Breather Breather Chamber Cover Removal • Remove the bolts [A] and the breather chamber cover [B]. Breather Chamber Cover Installation • Install a new gasket and the breather chamber cover, and tighten the bolts. Breather Valve Inspection • Remove the breather valve [A].
  • Page 108: Camshaft, Tappet

    7-10 CAMSHAFT/CRANKSHAFT Camshaft, Tappet Camshaft, Tappet Removal • Drain the oil (see Oil Change in the Lubrication System chapter). • Remove: Air Cleaner Elements (see Air Cleaner Element Removal in the Fuel System chapter) Recoil Starter (see Recoil Starter Removal in the Starter System chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System chapter)
  • Page 109: Camshaft, Tappet Installation

    CAMSHAFT/CRANKSHAFT 7-11 Camshaft, Tappet Camshaft, Tappet Installation • Apply engine oil to the following. Tappet Journal Camshaft Journal Cam Lobe Surface Camshaft Gear • Install the tappets in those old positions. • Align the punch marks [A] on the crankshaft gear and on the camshaft gear.
  • Page 110: Camshaft Bearing/journal Wear

    7-12 CAMSHAFT/CRANKSHAFT Camshaft, Tappet • Inspect the camshaft to make sure that its ACR (automatic compression reduction) function operates smoothly and does not have any damage or abnormal wear. If ACR parts are worn, replace the ACR with a new one. When the weight [A] is closed, if the top of the arm [B] is lower than the base [C], replace the ACR with a new one.
  • Page 111: Crankshaft, Connecting Rod

    CAMSHAFT/CRANKSHAFT 7-13 Crankshaft, Connecting Rod Connecting Rod Removal • Remove: Piston (see Piston Removal in the Engine Top End chap- ter) Connecting Rod Installation • Install: Piston (see Piston Installation in the Engine Top End chapter) Crankshaft Removal • Drain the oil (see Oil Change in the Lubrication System chapter).
  • Page 112: Connecting Rod Bend/twist

    7-14 CAMSHAFT/CRANKSHAFT Crankshaft, Connecting Rod Connecting Rod Bend/Twist • Measure the connecting rod bend. ○ Select an arbor of the same diameter of the connecting rod big end, and insert the arbor through the connecting rod big end. ○ Select an arbor of the same diameter of the piston pin and at least 100 mm (3.94 in.) long, and insert the arbor through the connecting rod small end.
  • Page 113: Connecting Rod Big End Bearing/crankpin Wear

    CAMSHAFT/CRANKSHAFT 7-15 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. Crankpin Width Service Limit: 24.17 mm (0.95 in.) Connecting Rod Big End Bearing/Crankpin Wear •...
  • Page 114: Crankshaft Main Journal/wear

    7-16 CAMSHAFT/CRANKSHAFT Crankshaft, Connecting Rod Crankshaft Main Journal/Wear • Measure both journals at several points around the jour- nal circumference. If the journal diameter is less than the service limit, re- place the crankshaft with a new one. Crankshaft Journal Diameter Service Limit: PTO Side [A] 27.96 mm (1.101 in.)
  • Page 115 STARTER SYSTEM 8-1 Starter System Table of Contents Exploded View........................Electric Starter System ......................Starter Motor Removal...................... Starter Motor Installation....................Starter Motor Inspection....................Recoil Starter System......................Recoil Starter Removal ..................... Recoil Starter Installation ....................Rope Guide Removal......................Rope Guide Installation..................... Pad Brake..........................
  • Page 116: Exploded View

    8-2 STARTER SYSTEM Exploded View...
  • Page 117 STARTER SYSTEM 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Recoil Starter Mounting Bolts 0.70 61 in·lb Brake Arm Mounting Bolt 0.95 82 in·lb Brake Lever Assembly Mounting Bolt 0.70 61 in·lb Starter Motor Mounting Bolts 0.70 61 in·lb Fuel Tank Cover Bolts 0.70 61 in·lb...
  • Page 118: Electric Starter System

    8-4 STARTER SYSTEM Electric Starter System Starter Motor Removal • Remove: Air Cleaner Elements (see Air Cleaner Element in the Fuel System chapter) Recoil Starter (see Recoil Starter Removal) Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) •...
  • Page 119: Recoil Starter System

    STARTER SYSTEM 8-5 Recoil Starter System Recoil Starter Removal • Remove: Recoil Starter Mounting Bolts [A] Recoil Starter [B] Recoil Starter Installation • Install the recoil starter and tighten the mounting bolts. Torque - Recoil Starter Mounting Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb) Rope Guide Removal •...
  • Page 120: Rope Guide Installation

    8-6 STARTER SYSTEM Recoil Starter System Rope Guide Installation • Set the guide so that the thick side [A] faces the outside [B], and press it with a suitable tool [C]. • Clamp the rope with the clip [A] so it can not wind back. •...
  • Page 121: Pad Brake

    STARTER SYSTEM 8-7 Pad Brake Pad Brake Assembly Removal • Remove: Air Cleaner Elements (see Air Cleaner Element Removal in the Fuel System chapter) Recoil Starter (see Recoil Starter Removal) Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) Pulley (see Flywheel Removal in the Electrical System chapter)
  • Page 122: Brake Switch Removal/installation

    8-8 STARTER SYSTEM Pad Brake • Tighten the bolt [A]. • Install the lever assembly [B]. • Tighten the brake lever assembly mounting bolt [C]. Torque - Brake Lever Assembly Mounting Bolt: 6.9 N·m (0.70 kgf·m, 61 in·lb) ○ Check the lever assembly moves smoothly after installa- tion.
  • Page 123 ELECTRICAL SYSTEM 9-1 Electrical System Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Wiring Diagram ........................Precautions..........................Charging System ........................Flywheel Removal......................Flywheel Installation......................9-10 Circuit Composition......................9-12 Action Principle ......................... 9-12 Cautions of Handling and Maintenance ................9-13 Charging Coil Inspection....................
  • Page 124: Exploded View

    9-2 ELECTRICAL SYSTEM Exploded View...
  • Page 125 ELECTRICAL SYSTEM 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Flywheel Bolt Spark Plug Kill Switch Bolt 0.15 13 in·lb 4. Modified Model DO: Degrease the taper.
  • Page 126: Specifications

    9-4 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Ignition System Ignition Coil: Primary Winding Resistance in the text – – – Secondary Winding Resistance in the text – – – Spark Plug: Type NGK BPR5ES – – – 0.75 mm (0.030 in.) –...
  • Page 127: Special Tools

    ELECTRICAL SYSTEM 9-5 Special Tools Hand Tester: Bracket Holder: 57001–1394 57001–1536...
  • Page 128: Wiring Diagram

    9-6 ELECTRICAL SYSTEM Wiring Diagram Recoil Starter Model...
  • Page 129 ELECTRICAL SYSTEM 9-7 Wiring Diagram Electric Starter Model...
  • Page 130: Precautions

    9-8 ELECTRICAL SYSTEM 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 hit the electric parts with a hammer or do not drop the electric parts.
  • Page 131: Charging System

    ELECTRICAL SYSTEM 9-9 Charging System Flywheel Removal • Remove: Air Cleaner Elements (see Air Cleaner Element Removal in the Fuel System chapter) Recoil Starter (see Recoil Starter Removal in the Starter System chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) •...
  • Page 132: Flywheel Installation

    9-10 ELECTRICAL SYSTEM Charging System • Using a suitable flywheel puller [A], remove the flywheel [B]. CAUTION Always use flywheel puller. • For Electric Starter model; note the following. • Remove: Ignition Coil with Charging Coil (see Ignition Coil Re- moval) •...
  • Page 133 ELECTRICAL SYSTEM 9-11 Charging System • For Electric Starter model; as shown in the figure. • For Recoil Starter model; note the following. • Install: Ignition Coil (see Ignition Coil Installation) Pad Brake Assembly (see Pad Brake Assembly Instal- lation in the Starter System chapter) •...
  • Page 134: Circuit Composition

    9-12 ELECTRICAL SYSTEM Charging System • For Modified model; note the following. • Install the pulley [A]. • Tighten the flywheel bolt [B]. Torque - Flywheel Bolt: 42 N·m (4.3 kgf·m, 31 ft·lb) • Install the removed parts (see appropriate chapters). Circuit Composition C: Condenser E: Exciter Coil...
  • Page 135: Cautions Of Handling And Maintenance

    ELECTRICAL SYSTEM 9-13 Charging System (3) Spark delay characteristic 1. The trigger position of the thyristor (SCR) changes and spark delay by decreasing the voltage wave form applied to the thyristor (SCR) in the revolutions number set up in the spark delay characteristic control circuit in the figure.
  • Page 136: Ignition System

    9-14 ELECTRICAL SYSTEM Ignition System Ignition Coil Removal • For Recoil Starter model; note the following. • Remove: Fan (see Flywheel Removal) Spark Plug Cap Ground Lead [A] Bolts [B] Ignition Coil [C] • For Electric Starter model; note the following. •...
  • Page 137: 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 138: Spark Plug Installation

    9-16 ELECTRICAL SYSTEM Ignition System Spark Plug Installation • Insert the spark plug vertically into the plug hole with the plug installed in the plug wrench. • Tighten the plug. Torque - Spark Plug: 22 N·m (2.2 kgf·m, 16 ft·lb) •...
  • Page 139 TROUBLESHOOTING 10-1 Troubleshooting Table of Contents Engine Troubleshooting Guide ....................10-2 Starter Motor Troubleshooting Guide ..................10-6...
  • Page 140 10-2 TROUBLESHOOTING Engine Troubleshooting Guide If the engine malfunctions, check if the way the engine is used is correct. If engine malfunctions even if engine is used correctly, systematically carry out troubleshooting starting with simple points. This chart describes typical troubleshooting procedures. Do not unnecessarily disassemble carburetor, magneto or engine unless it has been found to be the cause of malfunctioning.
  • Page 141 TROUBLESHOOTING 10-3 Engine Troubleshooting Guide...
  • Page 142 10-4 TROUBLESHOOTING Engine Troubleshooting Guide...
  • Page 143 TROUBLESHOOTING 10-5 Engine Troubleshooting Guide...
  • Page 144 10-6 TROUBLESHOOTING Starter Motor Troubleshooting Guide 1. Disconnect spark plug cap, and ground the cap terminal. 2. Turn engine switch to "START" position and check condition. WARNING Engine may be cranked in this test. Do not touch any rotating parts of engine and equip- ment during test.
  • Page 145 Part No.99924-2063-04 Printed in Japan...

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