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Kawasaki FR651V Service Manual

4-stroke air-cooled v-twin gasoline engine.
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For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983
FR651V, FR691V, FR730V
FS651V, FS691V, FS730V
FX651V, FX691V, FX730V
4-Stroke Air-Cooled V-Twin Gasoline Engine
Service Manual
www.mymowerparts.com

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Table of Contents

   Also See for Kawasaki FR651V

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   Summary of Contents for Kawasaki FR651V

  • Page 1 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FR651V, FR691V, FR730V FS651V, FS691V, FS730V FX651V, FX691V, FX730V 4-Stroke Air-Cooled V-Twin Gasoline Engine Service Manual www.mymowerparts.com...
  • Page 2 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com...
  • Page 3 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 Quick Reference Guide General Information Periodic Maintenance Fuel System Cooling System Engine Top End Lubrication System Camshaft/Crankshaft Starter System Electrical System Troubleshooting 10 j This quick reference guide will assist you in locating a desired topic or pro- cedure.
  • Page 4 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com...
  • Page 5 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FR651V, FR691V, FR730V FS651V, FS691V, FS730V FX651V, FX691V, FX730V 4-Stroke Air-Cooled V-Twin Gasoline Engine Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Consumer Products &...
  • Page 6 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C...
  • Page 7: Emission Control Information

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated 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

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 Foreword This manual is designed primarily for use by the Electrical System chapter. Then, use the trained mechanics in a properly equipped shop. Table of Contents on the first page of the chap- However, it contains enough detail and basic in- ter to find the Ignition Coil section.
  • Page 9 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................www.mymowerparts.com...
  • Page 10: General Information

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 1-2 GENERAL INFORMATION Before Servicing Before starting to service the engine, carefully read the applicable section to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been in- cluded wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is required for successful work.
  • Page 11 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 GENERAL INFORMATION 1-3 Before Servicing (12)Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally dam- ages seals. When pressing in a seal which has manufacturer’s marks, press it in with the marks facing out.
  • Page 12 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 1-4 GENERAL INFORMATION Before Servicing “Service Limits” indicate the usable limits. If the measurement shows excessive wear or deteri- orated performance, replace the damaged parts. www.mymowerparts.com...
  • Page 13 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 GENERAL INFORMATION 1-5 Model Identification FX Models FR Models www.mymowerparts.com...
  • Page 14 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 1-6 GENERAL INFORMATION Model Identification FS Models Cylinder Number Designation: No.1 Cylinder is the left-hand cylinder viewed from the inlet pipe. No.2 Cylinder is the right-hand cylinder viewed from the inlet pipe.
  • Page 15 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 GENERAL INFORMATION 1-7 General Specifications FR651V,FR691V,FR730V, FS651V,FS691V, FS730V, Item FX651V, FX691V, FX730V Type of Engine Forced air-cooled, vertical shaft, OHV, 4-stroke gasoline engine Cylinder Layout 90 V-Twin Bore × Stroke 78 mm × 76 mm (3.07 in. × 2.99 in.) Piston Displacement 726 cm³...
  • Page 16 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com...
  • Page 17: Table Of Contents

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... Special Tools .......................... Periodic Maintenance Procedures..................Fuel System......................... Low Idle Speed Adjustment ....................High Idle Speed Adjustment .....................
  • Page 18: Periodic Maintenance Chart

    • Clean combustion chambers (1): Service more frequently under dusty conditions. : These items must be performed with the proper tools. See your authorized Kawasaki Engine Dealer for service, unless you have the proper equipment and mechanical proficiency. www.mymowerparts.com...
  • Page 19: Torque And Locking Agent

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 PERIODIC MAINTENANCE 2-3 Torque and Locking Agent The following tables list the tightening torque for the major fasteners and the parts requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: EO: Apply oil to the threads.
  • Page 20 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 2-4 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Head Bolts (L = 60 mm) Rocker Arm Bracket Bolts 14.7 0.60 52 in·lb Rocker Cover Bolts Spark Plugs Valve Clearance Adjusting Locknuts 97 in·lb...
  • Page 21: Specifications

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 PERIODIC MAINTENANCE 2-5 Specifications Item Standard Fuel System Idle Speed (1): Low Idle Speed (Carburetor idle rpm) 1 450 r/min (rpm) Low Idle Speed (Governor idle rpm) 1 550 r/min (rpm) High Idle Speed...
  • Page 22: Special Tools

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 2-6 PERIODIC MAINTENANCE Special Tools Valve Seat Cutter, 45° - 35: Valve Seat Cutter, 45° - 30: 57001-1116 57001-1187 Valve Seat Cutter, 32° - 35: Valve Seat Cutter, 32° - 33: 57001-1121...
  • Page 23: Periodic Maintenance Procedures

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 PERIODIC MAINTENANCE 2-7 Periodic Maintenance Procedures Fuel System NOTE ○ High and low idle speeds may vary depending on the equipment on which the engine is used. Refer to the equipment specification.
  • Page 24: Fuel System Cleanliness Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 2-8 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING Always keep your hands clear of the moving parts. • Loosen the locknut [A], and unscrew the high idle set screw [B] few turns. •...
  • Page 25: Element Cleaning And Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 PERIODIC MAINTENANCE 2-9 Periodic Maintenance Procedures Element Cleaning and Inspection Air cleaner elements are not recommended to be cleaned, and each air cleaner element should be replaced with new ones at the maintenance time as shown in the maintenance chart.
  • Page 26: Air Cleaner Housing (cap And Body) Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 2-10 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Cleaner Housing (Cap and Body) Inspection FX Models • Remove: Elements (see Element Removal in the Fuel System chapter) Air Cleaner Housing (see Air Cleaner Body and Bracket Removal in the Fuel System chapter) •...
  • Page 27: Valve Clearance Adjustment

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 PERIODIC MAINTENANCE 2-11 Periodic Maintenance Procedures No.1 Cylinder ○ The left projection [A] on the flywheel is faced with the right leg [B] on the #1 ignition coil [C] as shown in the figure.
  • Page 28: Valve Seat Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Holding the adjusting bolt with a spanner [A], tighten the adjusting locknut [B] to the specified torque. Torque - Valve Clearance Adjusting Locknuts: 11 N·m (1.1 kgf·m, 87 in·lb)
  • Page 29: Periodic Maintenance

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Seat Cutter Operating Cares 1. This valve seat cutter is designed only for valve seat repair. Therefore the cutter must not be used for other purposes.
  • Page 30 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Coat the seat with machinist’s dye. • Fit a 45° cutter [A] to the holder and slide it into the valve guide. ○ Resurface the valve seat with a 45° cutter, removing only enough material to produce a smooth and concentric seat.
  • Page 31: Lubrication System

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • When lapping is completed, wash all parts in solvent to remove lapping compound. Dry the parts thoroughly. • Note the position of the lapping mark on the valve face.
  • Page 32: Oil Filter Replacement

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the oil filler cap and pour in the specified type and the amount of oil. Engine Oil: Grade: SF, SG, SH, SJ or SL Class...
  • Page 33: Electrical System

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Electrical System Spark Plug Cleaning and Inspection • Carefully pull the plug cap from the spark plug, and re- move the spark plug. If the plug is oily or has carbon built up on it, clean the plug using a high-flash point solvent and a wire brush or other suitable tools.
  • Page 34 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com...
  • Page 35 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-1 Fuel System Table of Contents Exploded View........................Specifications ......................... Governor Link Mechanism...................... 3-10 Control Panel Assembly Removal ..................3-10 Control Panel Assembly Installation ................. 3-10 Governor Arm Removal ....................
  • Page 36: Exploded View

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-2 FUEL SYSTEM Exploded View FX Models www.mymowerparts.com...
  • Page 37 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Cleaner Bracket Mounting Bolts 0.60 52 in·lb Air Cleaner Holder Bracket Bolts 0.60 52 in·lb Carburetor and Inlet Pipe Mounting Bolts 0.60...
  • Page 38 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-4 FUEL SYSTEM Exploded View FR651V, FR691V, FR730V, FS651V, FS691V, FS730V Models www.mymowerparts.com...
  • Page 39 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Carburetor and Inlet Pipe Mounting Nuts 0.60 52 in·lb Control Panel and Inlet Pipe Mounting Bolt 0.60 52 in·lb Inlet Manifold Bolts 0.60...
  • Page 40 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-6 FUEL SYSTEM Exploded View www.mymowerparts.com...
  • Page 41 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Control Panel Mounting Bolt 0.60 52 in·lb Governor Arm Clamp Nut 0.80 69 in·lb Governor Arm Joint Bolt 0.60 52 in·lb Governor Shaft Plate Screws 0.20...
  • Page 42: Specifications

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-8 FUEL SYSTEM Specifications Item Standard Carburetor Specifications: Make/Type: FR651V and FS651V Walbro/LMF-23 FR691V and FS691V Walbro/LMF-26 FR730V and FS730V Walbro/LMF-22 FX651V Nikki 621266-A61 FX691V Nikki 621266-A51 FX730V Nikki 621266-A01 Throttle Bore Diameter: FR and FS Models 30 mm (1.18 in.)
  • Page 43 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-9 Specifications Fuel (2) Fuel Requirement Unleaded regular grade gasoline US, Canada Using a minimum of 87 octane by antiknock index is recommended. Antiknock Index: (RON + MON)/2 RON = Research Octane Number...
  • Page 44: Governor Link Mechanism

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-10 FUEL SYSTEM Governor Link Mechanism Control Panel Assembly Removal FX Models • Remove: Inlet Pipe Mounting Bolt [A] and Nut [B] Control Panel Mounting Bolt [C] Choke Spring [D] Control Panel Assembly [E]...
  • Page 45: Governor Arm Removal

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-11 Governor Link Mechanism FR and FS Models • Install the governor spring [A], control panel assembly [B] and choke spring [C]. • Tighten: Torque - Control Panel Mounting Bolt [D]: 5.9 N·m (0.60 kgf·m, 52 in·lb)
  • Page 46: Governor Arm Installation

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-12 FUEL SYSTEM Governor Link Mechanism • Remove the bolt [A] to separate the governor arms [B]. Governor Arm Installation • Install the inside governor arm [A] onto the governor shaft [B].
  • Page 47: Governor Assembly Installation

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-13 Governor Link Mechanism Governor Assembly Installation • Fit the snap ring into the groove securely. • Turn the governor plate by hand and check that the steel balls and governor plate operate freely.
  • Page 48: Carburetor

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-14 FUEL SYSTEM Carburetor Fuel and Air Flow FX Models 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 49 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-15 Carburetor The pilot system includes the pilot jet [F], pilot screw [G] (Idle mixture screw), pilot outlet [H], and the bypass holes [I]. The pilot system meters the fuel/air mixture while the engine is idling and running under a light load.
  • Page 50 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-16 FUEL SYSTEM Carburetor FR and FS Models The main system of the carburetor consists of the main jet [A], main nozzle [B], and the main air passage [C] (main air jet [D]). The main system meters fuel to the engine dur- ing moderate to heavy load conditions.
  • Page 51: Fuel Shut Off Solenoid Valve

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-17 Carburetor Fuel Shut Off Solenoid Valve To avoid after firing when stopping the engine, a solenoid actuated fuel shut off solenoid valve [A] is installed in the carburetor bowl. The valve shuts off the fuel supply to the main jets [B] simultaneously when the switch key turned to the “OFF”...
  • Page 52: Main Jet Replacement

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-18 FUEL SYSTEM Carburetor Main Jet Replacement FX Models • Close the fuel shut off valve in the equipment. • Remove the carburetor (see Carburetor Removal). • Drain the fuel in the carburetor completely by unscrewing...
  • Page 53: Fuel System Cleanliness Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-19 Carburetor • Replace the main jet [A] with a new one for altitude ex- pected (see High Altitude Operation). • Install the new O-ring [B] to the main jet.
  • Page 54: Inlet Pipe Removal

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-20 FUEL SYSTEM Carburetor Inlet Pipe Removal FX Models • Remove: Air Cleaner (see Air Cleaner Body and Bracket Removal) Control Panel Assembly (see Control Panel Assembly Removal) Inlet Pipe Mounting Bolt [A] and Nut [B]...
  • Page 55: Carburetor Removal

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-21 Carburetor • Connect the breather hose [A] so that the clamp knob [B] faces the downward. • Install the removed parts (see appropriate chapters). FX Models [C] FR and FS Models [D]...
  • Page 56 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-22 FUEL SYSTEM Carburetor • Unhook the throttle link spring [A] at the throttle shaft lever clip end [B] with a long nose plier. • Unhook the throttle link rod [C] from the throttle shaft lever clip end.
  • Page 57: Carburetor Installation

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-23 Carburetor Carburetor Installation • Clean the mating surface of the carburetor and inlet man- ifold. • Replace the gaskets [A] with new ones. • Install the insulator [B], carburetor [C] and gaskets se- quence as shown in the figure.
  • Page 58 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-24 FUEL SYSTEM Carburetor • Install the throttle link rod [A] and spring [B] to the throttle shaft lever clip [C]. NOTE ○ Take care not to bend the throttle link rod during instal- lation.
  • Page 59: Carburetor Disassembly/assembly

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-25 Carburetor Carburetor Disassembly/Assembly FX Models • 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.
  • Page 60 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-26 FUEL SYSTEM Carburetor FR651V, FR691V, FS651V, FS691V Models • 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.
  • Page 61 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-27 Carburetor FR730V and FS730V Models • 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.
  • Page 62: Carburetor Cleaning

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-28 FUEL SYSTEM Carburetor Carburetor Cleaning WARNING Clean the carburetor in a well-ventilated area, and take care that there is no sparks or flame anywhere near the working area; this includes any appliance with a pilot light.
  • Page 63: Carburetor Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-29 Carburetor Carburetor Inspection WARNING Gasoline is extremely flammable and can be explo- sive under certain. Turn the engine switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks;...
  • Page 64: Fuel Shut Off Solenoid Valve Test

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-30 FUEL SYSTEM 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 push in and released.
  • Page 65: Inlet Manifold

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-31 Inlet Manifold Inlet Manifold Removal • Remove the engine shroud (see Engine Shroud Removal in the Cooling System chapter) • Unscrew the inlet manifold mounting bolts [A]. • Remove the inlet manifold [B] and gaskets.
  • Page 66: Inlet Manifold Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-32 FUEL SYSTEM Inlet Manifold Inlet Manifold Inspection • Inspect the intake manifold for cracks or porous casting. • Cracks not visible to the eye may be detected by using a metal crack detection system (Visual color check: com- monly found at automotive parts store.).
  • Page 67: Fuel Pump, Fuel Filter

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-33 Fuel Pump, Fuel Filter The diaphragm in the fuel pump operates by the pulse generated in the crankcase, and the fuel pump supplies fuel to the carburetor. The fuel pump disassembly is not recommended, if any damage for the pump is noticed replace it with a new one.
  • Page 68: Fuel Filter Removal/installation

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-34 FUEL SYSTEM Fuel Pump, Fuel Filter Fuel Flow Test WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the engine switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 69: Air Cleaner

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-35 Air Cleaner Element Removal FX Models • Unhook the two retaining clamps [A] and remove the cap [B] from the air cleaner body. • Remove the primary element [A].
  • Page 70: Element Installation

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-36 FUEL SYSTEM Air Cleaner • Loosen the clamp [A]. • Remove: Inlet Hose [B] Foam Element [C] (FS Models only) Element Installation FX Models • Slide the secondary element and primary element into place in the air cleaner body.
  • Page 71: Element Cleaning And Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 FUEL SYSTEM 3-37 Air Cleaner • Install the inlet hose [A], and tighten the clamp [B]. ○ Check that the element [C] is horizontally installed. • Install the inlet hose [A], and tighten the clamp [B].
  • Page 72: Air Cleaner Body And Bracket Installation

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 3-38 FUEL SYSTEM Air Cleaner • Remove: Bolts [A] Bracket [B] Air Cleaner Body and Bracket Installation FX Models • Install the air cleaner bracket [A]. • Tighten: Torque - Air Cleaner Bracket Mounting Bolts [B]: 5.9 N·m (0.60 kgf·m, 52 in·lb)
  • Page 73 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Cooling Fan ..........................Cooling Fan Removal ....................... Cooling Fan Installation ....................Cooling Fan Inspection ..................... Engine Shroud........................Engine Shroud Removal ....................Engine Shroud Installation ....................
  • Page 74 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 4-2 COOLING SYSTEM Exploded View www.mymowerparts.com...
  • Page 75 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cooling Fan Plate Mounting Bolts 0.90 78 in·lb Cooling Fan Screen Bolts 0.60 52 in·lb Engine Shroud Bolts (FX Models) 0.60 52 in·lb...
  • Page 76 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 4-4 COOLING SYSTEM Cooling Fan Cooling Fan Removal • Refer to the Flywheel and Stator Coil Removal in the Elec- trical System chapter. Cooling Fan Installation • Refer to the Flywheel and Stator Coil Installation in the Electrical System chapter.
  • Page 77 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 COOLING SYSTEM 4-5 Engine Shroud Engine Shroud Removal • Remove: Spark Plug Cap (see Ignition Coil Removal in the Elec- trical System chapter) Carburetor (see Carburetor Removal) Engine Shroud Bolts [A] Engine Shroud [B] FR and FS Models •...
  • Page 78 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 4-6 COOLING SYSTEM Engine Shroud FR and FS Models • Install the engine shrouds. NOTE ○ Bend the engine shroud (regulator side) [A] only within the shown range. 70° [B] • Attach the stator coil lead, ignition coil lead and solenoid valve connector lead to the engine shroud with the band.
  • Page 79 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Cylinder Head......................... Compression Measurement....................Cylinder Head Assembly Removal ................... Cylinder Head Assembly Installation ................Push Rod Removal ......................
  • Page 80: Exploded View

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 5-2 ENGINE TOP END Exploded View www.mymowerparts.com...
  • Page 81 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Connecting Rod Big End Cap Bolts 87 in·lb Cylinder Head Bolts (L = 50 mm) Cylinder Head Bolts (L = 60 mm) Rocker Arm Bracket Bolts 14.7...
  • Page 82: Specifications

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 5-4 ENGINE TOP END Specifications Item Service Limit Cylinder Head: Cylinder Compression (MIN) 440 kPa (64 psi) @ Engine Oil Temperature 50 60°C (122 144°F), Cranking Speed 450 rpm/5 Seconds Cylinder Head Warp 0.05 mm (0.002 in.)
  • Page 83 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-5 Specifications Item Standard Valve Clearance: Inlet, Exhaust 0.05 0.10 mm (0.0020 0.039 in.) Valve Seating Surface Angle: Inlet, Exhaust 45° Valve Seating Surface Width: Inlet 1.8 mm (0.047 0.071 in.)
  • Page 84: Special Tools

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 5-6 ENGINE TOP END Special Tools Piston Ring Pliers: Piston Ring Compressor Belt, 67 57001-115 57001-1097 Compression Gauge, 20 kgf/cm²: Compression Gauge Adapter, M14 × 1.25: 57001-221 57001-1159 Piston Ring Compressor Grip: 57001-1095 www.mymowerparts.com...
  • Page 85: Cylinder Head

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-7 Cylinder Head Compression Measurement • Before measuring compression, do 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 86: Cylinder Head Assembly Removal

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 5-8 ENGINE TOP END Cylinder Head Cylinder Head Assembly Removal • Remove: Inlet Manifold (see Inlet Manifold Removal in the Fuel System chapter) Spark Plugs (see Spark Plug Removal in the Electrical System chapter) •...
  • Page 87: Push Rod Removal

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-9 Cylinder Head • Set each piston at the T.D.C [A] of the compression stroke. • Put new gaskets and the cylinder head assemblies on each cylinder. NOTE ○...
  • Page 88: Push Rod Installation

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 5-10 ENGINE TOP END Cylinder Head Push Rod Installation • Set each piston at the T.D.C of the compression stroke. • Apply engine oil to the both ends and shaft of the push rod.
  • Page 89 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-11 Cylinder Head • Remove: Push Rod (see Push Rod Removal) Rocker Arm Bracket Bolts [A] Rocker Arm Bracket [B] • Remove the cylinder head assembly (see Cylinder Head Assembly Removal).
  • Page 90: Cylinder Head Cleaning

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 5-12 ENGINE TOP END Cylinder Head • Install the rocker arm brackets [A] so that bracket hollows [B] fit to the cylinder head projections [C]. • Apply a non-permanent locking agent to the rocker arm bracket bolts, and tighten them.
  • Page 91: Cylinder Head Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-13 Cylinder Head Cylinder Head Inspection • Lay a straightedge [A] across the mating surface of the head at several different points, and measure warp by inserting a thickness gauge [B] between the straightedge and head.
  • Page 92: Valves

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 5-14 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter.
  • Page 93: Valve Guide Inside Diameter

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-15 Valves Valve Guide Inside Diameter • Use a small bore gauge or a micrometer to measure the inside diameter [A] of the valve guide [B] at three positions down the guide length.
  • Page 94: Cylinder, Piston

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 5-16 ENGINE TOP END Cylinder, Piston Piston Removal • Remove: Cylinder Head Assembly (see Cylinder Head Assembly Removal) Crankcase Cover (see Crankcase Cover Removal in the Camshaft/Crankshaft chapter) Camshaft (see Camshaft, Tappet Removal in the Camshaft/Crankshaft chapter) •...
  • Page 95: Piston Installation

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-17 Cylinder, Piston • Remove the top and second rings with piston ring pliers. Special Tool - Piston Ring Pliers: 57001-115 • If the special tool is not available, carefully spread the ring opening with your thumbs, then push up to the opposite side of the ring [A] to remove it.
  • Page 96 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 5-18 ENGINE TOP END Cylinder, Piston • Apply engine oil to the piston pins. • Assemble the pistons onto the connecting rods as follow. ○ No.1 Cylinder Piston; align the arrow mark on the piston head with opposite “K”...
  • Page 97: Piston/cylinder Seizure

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-19 Cylinder, Piston CAUTION The connecting rod and the connecting rod big end cap are machined at the factory in the assembled state, so they must be replaced together as a set.
  • Page 98: Piston Ring And Ring Groove Wear

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 5-20 ENGINE TOP END Cylinder, Piston • Clean the piston ring grooves [A] with a broken piston ring or other suitable tools. CAUTION Be careful not to widen the ring grooves. Damaged ring grooves will require piston replacement.
  • Page 99: Piston Ring End Gap

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-21 Cylinder, Piston Piston Ring End Gap • Remove the piston rings (see Piston Removal). • Push each ring (one at a time) in the cylinder bore to a point close to the bottom of the cylinder bore.
  • Page 100: Piston Diameter

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 5-22 ENGINE TOP END Cylinder, Piston Piston Diameter • Measure the outside diameter [A] of the piston 11 mm (0.43 in.) [B] up from the bottom of the piston at a right angle to the direction of the piston pin hole.
  • Page 101 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ENGINE TOP END 5-23 Cylinder, Piston Change to a honing stone for finishing, the final bore di- ameter should be as shown in the table. Be sure the correct stone is used and the stone is not worn.
  • Page 102 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com...
  • Page 103 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 LUBRICATION SYSTEM 6-1 Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools .......................... Engine Oil and Oil Filter......................Engine Oil Level Inspection ....................Engine Oil Change......................
  • Page 104: Exploded View

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 6-2 LUBRICATION SYSTEM Exploded View www.mymowerparts.com...
  • Page 105 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 LUBRICATION SYSTEM 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Oil Drain Plug 0.70 61 in·lb Oil Filler Mounting Bolt (FX Models) 0.60 52 in·lb Oil Filter Mounting Bolt (FR and FS Models) 0.90...
  • Page 106: Engine Oil Flow Chart

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 6-4 LUBRICATION SYSTEM Engine Oil Flow Chart www.mymowerparts.com...
  • Page 107: Specifications

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 LUBRICATION SYSTEM 6-5 Specifications Item Standard Engine Oil: Grade SF, SG, SH, SJ or SL class Viscosity SAE40, SAE30, SAE10W-30/SAE10W-40, or SAE5W-20 Capacity: When the oil filter is not 1.8 L (1.9 US qt)
  • Page 108: Special Tools

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 6-6 LUBRICATION SYSTEM Special Tools Oil Pressure Gauge, 10 kgf/cm²: Oil Pressure Gauge Adapter, PT 1/8: 57001-164 57001-1033 www.mymowerparts.com...
  • Page 109: Engine Oil And Oil Filter

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 LUBRICATION SYSTEM 6-7 Engine Oil and Oil Filter CAUTION Engine operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure and accident. Engine Oil Level Inspection •...
  • Page 110: Pressurized Lubrication System

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 6-8 LUBRICATION SYSTEM Pressurized Lubrication System The engine lubrication circuit is a pressurized system consisting of a positive displacement pump which picks up oil through a filter screen from the crankcase. The oil is pumped to a replaceable oil filter cartridge, through the engine’s oil passages to lubricate internal components,...
  • Page 111: Oil Pump, Relief Valve

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 LUBRICATION SYSTEM 6-9 Oil Pump, Relief Valve Oil Pump, Relief Valve Removal • Remove: Crankcase Cover (see Crankcase Cover Removal in the Camshaft/Crankshaft chapter) Governor Shaft (see Governor Shaft Removal in the Fuel...
  • Page 112 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 6-10 LUBRICATION SYSTEM Oil Pump, Relief Valve • 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.
  • Page 113: Oil Screen

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 LUBRICATION SYSTEM 6-11 Oil Screen Oil Screen Removal • Remove the oil pump cover plate (see Oil Pump, Relief Valve Removal). • Remove the oil screen [A]. Oil Screen Installation • Clean the oil screen thoroughly whenever it is removed for any reason (see Cleaning and Inspection).
  • Page 114 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com...
  • Page 115 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 CAMSHAFT/CRANKSHAFT 7-1 Camshaft/Crankshaft Table of Contents Exploded View........................Specifications ......................... Special Tool ..........................Crankcase ..........................Crankcase Cover Removal ....................Crankcase Cover Disassembly..................Crankcase Cover Assembly....................Crankcase Cover Installation .................... Crankcase Cover Inspection.....................
  • Page 116: Exploded View

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 7-2 CAMSHAFT/CRANKSHAFT Exploded View www.mymowerparts.com...
  • Page 117 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 CAMSHAFT/CRANKSHAFT 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Connecting Rod Big End Cap Bolts 87 in·lb Crankcase Cover Bolts 27.4 Crankcase Cover Oil Passage Plugs 0.40 35 in·lb Crankcase Oil Passage Plugs 0.40...
  • Page 118: Specifications

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 7-4 CAMSHAFT/CRANKSHAFT Specifications Item Service Limit Camshaft, Tappet: Cam Lobe Height: Inlet 29.36 mm (1.156 in.) Exhaust 29.36 mm (1.156 in.) Camshaft Journal Diameter: PTO Side 15.99 mm (0.630 in.) Flywheel Side 15.99 mm (0.630 in.)
  • Page 119: Special Tool

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 CAMSHAFT/CRANKSHAFT 7-5 Special Tool Bearing Driver Set: 57001-1129 www.mymowerparts.com...
  • Page 120: Crankcase

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 7-6 CAMSHAFT/CRANKSHAFT Crankcase Crankcase Cover Removal • Set the engine on a clean surface while parts are being removed. • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter).
  • Page 121: Crankcase Cover Assembly

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 CAMSHAFT/CRANKSHAFT 7-7 Crankcase Crankcase Cover Assembly • Chip the old gasket from the mating surfaces of the crankcase and cover. • Using compressed air, blow out the oil passage in the crankcase cover.
  • Page 122: Crankcase Cover Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 7-8 CAMSHAFT/CRANKSHAFT Crankcase • Check to see that the dowel pins [A], O-rings [B] and plas- tic pipe [C] are in place on the crankcase. • Install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence as shown in the figure.
  • Page 123: Crankcase Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 CAMSHAFT/CRANKSHAFT 7-9 Crankcase • Be sure to replace any oil seal with a new one if removed. ○ Apply mineral oil to the crankshaft oil seal outside. ○ Install the oil seal so that the marks [A] face out.
  • Page 124: Breather

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 7-10 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. A sealed-type crankcase emission control system is used to prevent blow-by gases from emitting in the air.
  • Page 125 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 CAMSHAFT/CRANKSHAFT 7-11 Breather FR and FS Models www.mymowerparts.com...
  • Page 126: Breather Valve Removal

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 7-12 CAMSHAFT/CRANKSHAFT Breather Breather Valve Removal • Remove: Stator Coil (see Flywheel and Stator Coil Removal in the Electrical System chapter) • Unscrew the bolts [A] and remove the clamps [B]. •...
  • Page 127: Breather Valve Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 CAMSHAFT/CRANKSHAFT 7-13 Breather Breather Valve Inspection • Inspect the reed valve [A] for breakage, crack or distor- tion, replace it with a new one if necessary. • Inspect the plate [B] for damage or rough contact surface, replace it with a new one if necessary.
  • Page 128: Camshaft, Tappet

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 7-14 CAMSHAFT/CRANKSHAFT Camshaft, Tappet Camshaft, Tappet Removal • Set the engine on a clean surface while parts are re- moved. • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter).
  • Page 129: Camshaft Assembly

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 CAMSHAFT/CRANKSHAFT 7-15 Camshaft, Tappet Camshaft Assembly • Install the governor assembly (see Governor Assembly Installation in the Fuel System chapter). • After assembling the camshaft, check the following items. ○ The governor plate [A] must move freely.
  • Page 130 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 7-16 CAMSHAFT/CRANKSHAFT Camshaft, Tappet • Measure the inside diameter [A] of the camshaft insert on the crankcase cover at several points. If the inside diameter is more than the service limit, re- place the crankcase cover with a new one.
  • Page 131: Crankshaft, Connecting Rod

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 CAMSHAFT/CRANKSHAFT 7-17 Crankshaft, Connecting Rod Connecting Rod Removal • Remove the piston (see Piston Removal in the Engine Top End chapter). Connecting Rod Installation • Install the piston (see Piston Installation in the Engine Top End chapter).
  • Page 132: Connecting Rod Bend/twist

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 7-18 CAMSHAFT/CRANKSHAFT Crankshaft, Connecting Rod Connecting Rod Bend/Twist • Measure the connecting rod bend. ○ Select an arbor [A] of the same diameter as the connect- ing rod big end, and insert the arbor through the connect- ing rod big end.
  • Page 133: Connecting Rod Big End Bearing/crankpin Wear

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 CAMSHAFT/CRANKSHAFT 7-19 Crankshaft, Connecting Rod • Measure the crankpin width [A] with a dial caliper. If the crankpin width is more than the service limit, replace the crankshaft with a new one.
  • Page 134: Crankshaft Main Journal/wear

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 7-20 CAMSHAFT/CRANKSHAFT Crankshaft, Connecting Rod Crankshaft Main Journal/Wear • Measure both main journals at several points around the journal circumference. If the journal diameter is less than the service limit, re- place the crankshaft with a new one.
  • Page 135 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 STARTER SYSTEM 8-1 Starter System Table of Contents Exploded View........................Specifications ......................... Electric Starter System ......................Starter Motor Removal...................... Starter Motor Installation....................Starter Solenoid and Circuit Test ..................Starter Motor Test ......................
  • Page 136: Exploded View

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 8-2 STARTER SYSTEM Exploded View www.mymowerparts.com...
  • Page 137 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 STARTER SYSTEM 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Starter Motor Mounting Bolts 19.6 Starter Motor Through Bolts (FR and FS 3.95 0.40 35 in·lb Models) 3. FR and FS Models G: Apply grease.
  • Page 138: Specifications

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 8-4 STARTER SYSTEM Specifications Item Standard Service Limit Electric Starter System Starter Motor: Carbon Brush Lengh: FX Models 10.0 mm (0.39 in.) 6.0 mm (0.24 in.) FR and FS Models – – –...
  • Page 139: Electric Starter System

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 STARTER SYSTEM 8-5 Electric Starter System Starter Motor Removal • Disconnect the wire. • Remove the mounting bolts [A] and pull the starter motor [B] from the engine with the switch lead attached.
  • Page 140: Starter System

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 8-6 STARTER SYSTEM Electric Starter System • Measure the continuity of the solenoid when activated. ○ Set the hand tester selector switch to the R × 1 Ω position and connect the leads across the large terminals [A] as shown in the figure.
  • Page 141: Starter Motor Test

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 STARTER SYSTEM 8-7 Electric Starter System Starter Motor Test NOTE ○ Always inspect the Starter Solenoid and Circuit Test section before starting following procedures. • Remove the starter motor (see Starter Motor Removal).
  • Page 142 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 8-8 STARTER SYSTEM Electric Starter System • Remove the insulator [A]. • Remove the springs [A]. • Free the brushes [B] from the brush holder [C]. • Remove: Brush Holder [A] Yoke [B] •...
  • Page 143: Starter Motor Assembly

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 STARTER SYSTEM 8-9 Electric Starter System FR and FS Models • Remove: Through Bolts [A] Brush Plate Assembly [B] • Remove: York [A] Nut [B] Washer [C] Spring [D] Pinion Gear [E]...
  • Page 144 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 8-10 STARTER SYSTEM Electric Starter System • Install the pinion clutch [A]. • Install the rear stopper [B] so that the hollow side face the outside. • Install the snap ring [C] to the groove of the shaft.
  • Page 145 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 STARTER SYSTEM 8-11 Electric Starter System • Install the insulator [A]. • Install the end cover so that the slit [A] fit the groove [B] of the grommet. • Tighten the through bolts.
  • Page 146: Starter Motor Brush Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 8-12 STARTER SYSTEM Electric Starter System • Apply grease to the armature shaft. • Install the end cover so that the slit [A] fit the projection [B] of the yoke. • Tighten: Torque - Starter Motor Through Bolts: 3.95 N·m (0.40...
  • Page 147: Armature Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 STARTER SYSTEM 8-13 Electric Starter System Armature Inspection • Inspect the surface of the commutator [A]. If it is scratched or dirty, polish it with a piece of very fine emery cloth [B], and clean out the grooves.
  • Page 148: Yoke Assembly Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 8-14 STARTER SYSTEM Electric Starter System • Measure the armature winding resistance. ○ Set the multimeter selector switch to the R × 1 Ω position and check the resistance between each segment and all the others.
  • Page 149: Pinion Clutch Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 STARTER SYSTEM 8-15 Electric Starter System • Set the multimeter selector switch to the R × 1 Ω posi- tion and measure the resistance between the negative brushes and starter motor yoke.
  • Page 150 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com...
  • Page 151 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ELECTRICAL SYSTEM 9-1 Electrical System Table of Contents Exploded View........................Specifications ......................... Special Tool ..........................Wiring Dagram........................Precautions..........................Charging System ........................9-10 Flywheel and Stator Coil Removal..................9-10 Flywheel and Stator Coil Installation.................
  • Page 152: Exploded View

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 9-2 ELECTRICAL SYSTEM Exploded View www.mymowerparts.com...
  • Page 153 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ELECTRICAL SYSTEM 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Flywheel Bolt Ignition Coil Bolts 0.60 52 in·lb Spark Plugs Stator Coil Screws 0.35 30 in·lb 6. FR and FS Models 7.
  • Page 154: Specifications

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 9-4 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Charging System Regulated Output Voltage 14.1 V DC 15 V DC 0.14 Ω Stator Coil Resistance – – – Unregulated Stator Output 34 V AC/3 000 rpm...
  • Page 155: Special Tool

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ELECTRICAL SYSTEM 9-5 Special Tool Hand Tester: 57001-1394 www.mymowerparts.com...
  • Page 156: Wiring Dagram

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 9-6 ELECTRICAL SYSTEM Wiring Dagram FX Models www.mymowerparts.com...
  • Page 157 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ELECTRICAL SYSTEM 9-7 Wiring Dagram FR Models www.mymowerparts.com...
  • Page 158 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 9-8 ELECTRICAL SYSTEM Wiring Dagram FS Models www.mymowerparts.com...
  • Page 159: Precautions

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 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 160: Charging System

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 9-10 ELECTRICAL SYSTEM Charging System Flywheel and Stator Coil Removal FX Models • Remove: Air Cleaner (see Air Cleaner Body and Bracket Removal in the Fuel System chapter) Fuel Pump (see Fuel Pump Removal in the Fuel System...
  • Page 161 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ELECTRICAL SYSTEM 9-11 Charging System FR Models • Remove: Paper Element (see Element Removal in the Fuel Sys- tem chapter) Fuel Pump (see Fuel Pump Removal in the Fuel System chapter) Bolts [A]...
  • Page 162: Flywheel And Stator Coil Installation

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 9-12 ELECTRICAL SYSTEM Charging System FR and FS Models • Cut off the band [A]. FR Models [B] FS Models [C] Flywheel and Stator Coil Installation • Install the stator coil and hold the stator coil lead to the clamp.
  • Page 163 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ELECTRICAL SYSTEM 9-13 Charging System • Install the fan [A]. • Install the plate [B] so that the slits [C] fit to the bosses [D] on the fan. • Tighten: Torque - Cooling Fan Plate Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
  • Page 164: Charging System Operational Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 9-14 ELECTRICAL SYSTEM Charging System FS Models • For the , note the following. • Install the fan housing. • Tighten: Torque - Fan Housing Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) •...
  • Page 165: Stator Coil Resistance

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ELECTRICAL SYSTEM 9-15 Charging System Stator Coil Resistance • Disconnect the stator coil lead connector [A]. • Measure the stator coil resistance. (Electric Starter Model) ○ Connect an ohmmeter between stator pins [B].
  • Page 166: Regulator Installation

    FS and FX Models • Remove the regulator (see Regulator Removal). • Set the KAWASAKI Hand Tester selector switch to the R × 100 Ω position. • Connect the test leads to the points shown on the chart and read the resistance.
  • Page 167: Ignition System

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ELECTRICAL SYSTEM 9-17 Ignition System This engine ignition is controlled by a solid state ignition assembly and requires no periodic main- tenance except for the spark plugs. The system consists of the following:...
  • Page 168: Ignition Coil Removal

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 9-18 ELECTRICAL SYSTEM Ignition System Ignition Coil Removal • Remove: Fan Housing (see Flywheel and Stator Coil Removal) Spark Plug Cap [A] Bolts [B] Stop Switch Lead Connector [C] Ignition Coil [D] Ignition Coil Installation •...
  • Page 169: Ignition Coil Inspection

    For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 ELECTRICAL SYSTEM 9-19 Ignition System Ignition Coil Inspection • Remove the ignition coil (see Ignition Coil Removal). • Measure the winding resistance as follows. ○ Set the hand tester to the R × 1 kΩ range.
  • Page 170 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com...
  • Page 171 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 TROUBLESHOOTING 10-1 Troubleshooting Table of Contents Engine Troubleshooting Guide ....................10-2 Starter Motor Troubleshooting Guide ..................10-6 www.mymowerparts.com...
  • Page 172 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 10-2 TROUBLESHOOTING Engine Troubleshooting Guide If the engine malfunctions, check if the way the engine is used is correct. If the engine malfunc- tions even if the engine is used correctly, systematically carry out troubleshooting starting with simple points.
  • Page 173 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 TROUBLESHOOTING 10-3 Engine Troubleshooting Guide www.mymowerparts.com...
  • Page 174 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 10-4 TROUBLESHOOTING Engine Troubleshooting Guide www.mymowerparts.com...
  • Page 175 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 TROUBLESHOOTING 10-5 Engine Troubleshooting Guide www.mymowerparts.com...
  • Page 176 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 10-6 TROUBLESHOOTING Starter Motor Troubleshooting Guide 1. Disconnect spark plug caps from the spark plugs. 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 177 For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983 Part No.99924-2093-01 Printed in Japan www.mymowerparts.com...

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  • Neil Bernard Mar 28, 2017 01:22:
    What does the pulse tube connect to?