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Whenever you see the symbols shown below,
heed their instructions! Always follow safe operat-
ing and maintenance practices.
This warning symbol identifies special in-
structions or procedures which, if not cor-
rectly followed, could result in personal
injury, or loss of life.
© Kawasaki Heavy Industries, Ltd. 1997, 1998, 1999, 2000, 2001
This caution symbol identifies special in-
structions or procedures which, if not strictly
observed, could result in damage to, or de-
struction of equipment.
Indicates points of particular interest for more effi-
cient and convenient operation.
Twelfth Edition (1): Dec. 2010 (M)


Table of Contents

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   Summary of Contents for Kawasaki FH451V

  • Page 1 READ THE OPERATING INSTRUCTIONS OF THE EQUIPMENT THIS ENGINE POWERS. © Kawasaki Heavy Industries, Ltd. 1997, 1998, 1999, 2000, 2001 Twelfth Edition (1): Dec. 2010 (M)
  • Page 2 Always remove the spark plug cap from spark plug when servicing the engine to prevent accidental starting. Read warning labels which are on the engine and understand them. If any label is missing, damaged, or worn get a replacement from your Kawasaki engine dealer and install it in the correct position.
  • Page 3 U.S.A. Emission Control Information To protect the environment in which we all live, Kawasaki has incorporated an exhaust emission control sys- tem in compliance with applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board. Also, depending on when your engine was produced, it may have an assigned emissions durability period.
  • Page 4 The Kawasaki Limited Emission Control System Warranty requires that you return your engine to an autho- rized Kawasaki dealer for remedy under warranty. Please read the warranty carefully, and keep it valid by complying with the owner’s obligations it contains.
  • Page 5 Tampering with Emission Control System Prohibited Federal law and California State law prohibit the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new engine for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the engine after such device or element of design has been removed or rendered inoperative by any person.
  • Page 6 FOREWORD We wish to thank you for choosing this Kawasaki Engine. Please read this Owner’s Manual and understand thoroughly before operating, as it contains information which will be of value in obtaining maximum service from your Kawasaki Engine. To ensure a long, trouble-free life for your engine, give it the proper care and maintenance described in this manual.
  • Page 8: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION......Throttle Cable Installation, Adjustment..Location of Parts ........... Choke Adjustment Associated Choke Type Engine Serial Number ........Separate Choke Type........Tune-up Specifications ........Throttle Cable Installation, Adjustment..Engine Oil Capacity ........Choke Cable Installation, Adjustment ..FUEL AND OIL RECOMMENDATIONS ..
  • Page 9: General Information

    GENERAL INFORMATION GENERAL INFORMATION Location of Parts [Recoil Starter Model] G. Engine Serial Number A. Recoil Starter F. Air Cleaner B. Oil Gauge/Filler H. Fuel Pump I. Fuel Filter C. Oil Filter D. Spark Plug J. Label-Manual E. Oil Drain K.
  • Page 10 GENERAL INFORMATION [Electric Starter Model] G. Engine Serial Number L. Electric Starter A. Air-intake Screen F. Air Cleaner M. Voltage Regulator B. Oil Gauge/Filler H. Fuel Pump C. Oil Filter I. Fuel Filter D. Spark Plug J. Label-Manual E. Oil Drain K.
  • Page 11: Engine Serial Number

    GENERAL INFORMATION Engine Serial Number Tune-up Specifications The engine serial number is the only means of ITEM Specifications identifying your particular engine from others of the Ignition Timing Unadjustable same model type. This engine serial number is needed by your Spark Plugs: CHAMPION...RCJ8Y dealer when ordering parts.
  • Page 12: Engine Oil Capacity

    GENERAL INFORMATION Engine Oil Capacity 1.5 L (1.6 US·qt) FH451V [when oil filter is not removed] FH500V 1.7 L (1.8 US·qt) FH531V [when oil filter is removed]...
  • Page 13: Fuel And Oil Recommendations

    FUEL AND OIL RECOMMENDATIONS FUEL AND OIL RECOMMENDATIONS ETHANOL: (Ethyl or Grain Alcohol) Fuel You may use gasoline containing up to 10% ethanol by volume. Use only clean, fresh, unleaded regular grade gasoline. MTBE: (Methyl Tertiary Butyl Ether) You may use gasoline containing up to 15% MTBE CAUTION by volume.
  • Page 14: Engine Oil

    FUEL AND OIL RECOMMENDATIONS Engine Oil The following engine oils are recommended. API Service Classification : SF, SG, SH, or SJ. Oil Viscosity Choose the viscosity according to the temperature as follows: NOTE ○ Using multi grade oils (5W-20, 10W–30, and 10W–40) will increase oil consumption.
  • Page 15: Preparation

    PREPARATION PREPARATION Fuel Engine Oil Check the engine oil daily before starting the en- WARNING gine otherwise shortage of the engine oil may cause serious damage to the engine such as seizure. Gasoline is extremely flammable and can be • Place the engine on level surface.
  • Page 16 PREPARATION Engine Oil Capacity 1.5 L (1.6 US·qt) FH451V [when oil filter is not removed] FH500V 1.7 L (1.8 US·qt) FH531V [when oil filter is removed] CAUTION The engine is shipped without engine oil.
  • Page 17: Starting

    STARTING STARTING • Use fresh gasoline. • Start Engine Protect the engine or the equipment from direct exposure to weather when not in operation. • Before starting the engine, insure all possible ex- WARNING ternal loads are disconnected. • Open the fuel valve on the equipment. Exhaust gases contain carbon monoxide, a •...
  • Page 18 STARTING CAUTION Whenever you start engine, make sure warn- ing light is not illuminated after engine starts. If warning light comes on, stop engine imme- diately and check oil level (If equipped).
  • Page 19 STARTING [Starting by Recoil Starter] [Starting by Electric Starter] • • Pull the starter cord slowly until you feel compres- Put the switch key into the engine switch. • sion, then pull it briskly. Turn the switch key to the START position on the equipment.
  • Page 20: Warming Up

    STARTING CAUTION Warming Up Allow engine to warm up sufficiently (3 to 5 minutes at idle) before applying a load. This After the engine starts, move the throttle lever (A) will allow oil to reach all engine parts, and on the equipment to halfway between “FAST” and allow piston clearance to reach design spec- “SLOW”.
  • Page 21: Operating

    OPERATING OPERATING CAUTION Engine Inclination Do not operate this engine continuously at angles exceeding 25° in any direction. En- This engine will operate continuously at angles up gine damage could result from insufficient to 25° in any direction. lubrication. Refer to the operating instructions of the equip- ment this engine powers.
  • Page 22: Stopping

    STOPPING STOPPING Ordinary Stop Emergency Stop • • Lower the engine speed to an idle. Keep running Immediately turn the engine switch or the key at idle for about one minute. switch to “OFF” position. • Close the fuel valve on the equipment. CAUTION For Control Panel Switch Type, move the throttle lever on the equipment against its low speed end.
  • Page 23: Adjustment

    ADJUSTMENT ADJUSTMENT Two types of choke control are used for FH451V, Make sure that the carburetor choke valve (H) FH500V, FH531V Model Engine. is closed completely when the throttle lever on the equipment is moved to “CHOKE” position. If not, Associated choke type perform “CHOKE ADJUSTMENT”.
  • Page 24 ADJUSTMENT Associated choke type...
  • Page 25: Separate Choke Type

    (D), and loosely clamp the choke cable outer If adjustment is needed, it performed by your au- housing (L) with the cable clamp bolt (B). thorized Kawasaki Engine dealer. • Move the equipment choke control to “OPEN” po- sition. Make sure that the carburetor choke valve...
  • Page 26 ADJUSTMENT Separate choke type...
  • Page 27: Maintenance

    MAINTENANCE MAINTENANCE Periodic Maintenance Chart WARNING Always remove the spark plug cap from spark plug when servicing the engine to prevent accidental starting. INTERVAL MAINTENANCE First Every 25 Every 50 Every Every Every Daily 8 hr. 100 hr. 200 hr. 300 hr.
  • Page 28 ○ The service intervals indicated are to be used as a guide. Service should be performed more frequently as determined by operating condition. : Service more frequently under dusty conditions. K: Have an authorized Kawasaki Engine dealer perform these services.
  • Page 29: Oil Level Check

    MAINTENANCE Oil Level Check Oil Change Check oil level daily and before each time of oper- Change oil after first 8 hours of operation. There- ation. Be sure oil level is maintained. See PREPA- after change oil every 100 hours. •...
  • Page 30: Oil Filter Change

    MAINTENANCE • Install the oil drain plug. • Oil Filter Change Remove oil gauge and refill with new oil (See FUEL AND OIL RECOMMENDATIONS). • • Check the oil level (see PREPARATION for oil Change the oil filter every 200 hours of operation. level check).
  • Page 31: Air Cleaner Service

    MAINTENANCE Air Cleaner Service CAUTION Do not run the engine with the air cleaner removed. Foam Element Clean the foam element (A) every 25 hours. • Wash the element in detergent and water, and dry it thoroughly. WARNING Engine oil is a toxic substance. Dispose of used oil properly.
  • Page 32: Fuel Filter And Fuel Pump Service

    MAINTENANCE Paper Element Fuel Filter and Fuel Pump Service Clean the paper element (B) every 50 hours. • Clean the element by tapping gently to remove dust. If very dirty, replace the element with a new WARNING one. • Replace with a new paper - element yearly or 200 Improper use of solvents can result in fire or hours.
  • Page 33: Spark Plug Service

    MAINTENANCE RECOMMENDED SPARK PLUG Spark Plug Service CHAMPION ........RCJ8Y WARNING Hot engine components can cause severe burns. Stop engine and allow it to cool before check- ing spark plug. Clean or replace the spark plug and reset gap (B) every 100 hours of operation. •...
  • Page 34: Cooling System Cleaning

    MAINTENANCE F : Hexagon socket button head bolt Cooling System Cleaning Electric Starter Model Before each use, check that the air-intake (rotary) screen (A) is free from grass and debris and clean if necessary. Every 100 hours of operation, check and clean the cooling fins and inside of engine shrouds to remove grass, chaff or dirt clogging the cooling system and causing overheating.
  • Page 35 MAINTENANCE Recoil Starter Model...
  • Page 36: Storage

    STORAGE STORAGE WARNING Fuel System Draining Gasoline is a toxic substance. Dispose of gasoline properly. Contact your local author- Engines to be stored over 30 days should be com- ities for approved disposal methods. pletely drained of fuel to prevent gum deposits form- •...
  • Page 37 STORAGE engine until you feel compression and then leave it there. This blocks the air inside the cylinder and prevents rust inside the engine. • Wipe the body with oily cloth. • Wrap the engine with plastic sheeting and store it in a dry place.
  • Page 38: Troubleshooting Guide

    TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE If the engine malfunctions, carefully examine the symptoms and the operating conditions, and use the table below as a guide to troubleshooting. Symptom Probably Cause Remedy Faulty piston, cylinder, piston ring, and Insufficient compression head gasket Faulty valves Loose spark plug Tighten properly...
  • Page 39 Faulty governor increase K : Have an authorized Kawasaki engine dealer perform these service. M : For Control Panel Switch Type, move the throttle lever on the equipment away from its low speed end to turn the engine switch to “ON”.
  • Page 40: Environmental Protection

    To protect our environment, properly discard used batteries, engine oil, gasoline, coolant, or other compo- nents that you might dispose of in the future. Consult you authorized Kawasaki dealer or local environmental waste agency for their proper disposal pro- cedure.
  • Page 41: Specifications

    SPECIFICATIONS SPECIFICATIONS FH451V, FH500V, FH531V Type of engine Air-cooled, 4-stroke OHV, V-twin cylinder, gasoline engine Bore x Stroke 68 x 68 mm (2.68 x 2.68 in.) Displacement 494 mL (30.15 Ignition System Solid–state ignition Direction of rotation Counterclockwise facing the PTO Shaft...
  • Page 42: Wiring Diagram

    WIRING DIAGRAM WIRING DIAGRAM (Recoil Starter Model) NOTE ○ Portion Surrounded by hatching Shows Kawasaki Procurement Parts.
  • Page 43 WIRING DIAGRAM (Electric Starter Model) With 12 - 13 V Charging Coil With 12 - 13 V Charging Coil NOTE ○ Portion Surrounded by hatching Shows Kawasaki Procurement Parts.
  • Page 44 For electrical safety, always remove cable from negative (–) side of battery before at- tempting any repair or maintenance. Battery Capacity Recommended Model FH451V, FH500V, FH531V Lawn Mower 12 V 200 CCA Class Snow Thrower 12 V 280 CCA Class...

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