Download  Print this page

Kawasaki FH381V Service Manual

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

Advertisement

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 Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been
taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such
changes to products manufactured previously.
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.
© 2001 Kawasaki Heavy Industries, Ltd.
FH381V FH430V
First Edition (1) : Oct. 1, 2001 (K)

Advertisement

Table of Contents

   Also See for Kawasaki FH381V

   Related Manuals for Kawasaki FH381V

   Summary of Contents for Kawasaki FH381V

  • Page 1 Quality Assurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.
  • Page 2 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 degree(s) Celsius revolution direct current revolution(s) per minute...
  • Page 3: 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 4: How To Use This Manual

    • Be alert for problems and non-scheduled maintenance. • Use proper tools and genuine Kawasaki engine parts. This note symbol indicates points of particular in- Genuine parts provided as spare parts are listed in the terest for more efficient and convenient operation.
  • Page 5: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing................................1-2 Model Identification ................................1-4 General Specifications ..............................1-5 Torque and Locking Agent..............................1-6 Special Tools..................................1-8...
  • Page 6: 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 included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is required for successful work. Especially note the following: (1) Dirt Before removal and disassembly, clean the engine.
  • Page 7 GENERAL INFORMATION 1-3 Before Servicing (15) Cotter Pin Replace any cotter pins that were removed with new ones, as removal deforms and breaks them. (16) Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film.
  • Page 8: Model Identification

    1-4 GENERAL INFORMATION Model Identification Electric Starter Model Recoil Starter Model Cylinder Number Designation: No.1 Cylinder is the left-hand cylinder viewed from the air cleaner. No.2 Cylinder is the right-hand cylinder viewed from the air cleaner.
  • Page 9: General Specifications

    GENERAL INFORMATION 1-5 General Specifications Items FH381V, FH430V Type of engine Forced air-cooled, vertical shaft, OHV, 4-stroke gasoline engine. Cylinder layout 90 V-Twin Bore x Stroke 65 mm x 65 mm (2.56 in x 2.56 in) Piston displacement 431 mL (26.3 cu. in)
  • Page 10: Torque And Locking Agent

    1-6 GENERAL INFORMATION 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: L : Apply a non-permanent locking agent to the threads. M : Apply a molybdenum disulfide lubricant (grease or oil) to the threads, seated surface, or washer.
  • Page 11 GENERAL INFORMATION 1-7 Torque and Locking Agent Fastener Remarks Torque kgf m ft lb Lubrication System: Engine Drain Plugs 0.70 61 in lb Oil Passage Plug 0.40 35 in lb Oil Pump Cover Plate Mounting Bolts 0.60 52 in lb Oil Filter in the text Camshaft/Crankshaft:...
  • Page 12: Special Tools

    1-8 GENERAL INFORMATION Special Tools Piston Ring Pliers: 57001–115 Piston Ring Compression Belt, Ø55 – Ø67: 57001–1096 Oil Pressure Gauge, 5kgf/cm : 57001–125 Valve Seat Cutter, 45 - Ø27.5: 57001–1114 Compression Gauge: 57001–221 Valve Seat Cutter, 32 - Ø25.0: 57001–1118 Oil Pressure Gauge Adapter, PT 1/8: 57001–1033 Valve Seat Cutter, 32 - Ø28.0: 57001–1119 Piston Ring Compression Grip: 57001–1095...
  • Page 13 GENERAL INFORMATION 1-9 Special Tools Compression Gauge Adapter M14 x 1.25: 57001–1159 Kawasaki Bond (Silicone Sealant) : 56019–120 Oil Filter Wrench: 57001–1249 Valve Seat Cutter Holder Ø6: 57001–1360 Hand Tester: 57001–1394...
  • Page 15: Periodic Maintenance

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart..............................2-2 Specifications ..................................2-3 Periodic Maintenance Procedures............................ 2-4 Fuel System...................................2-4 Low Idle Speed Adjustment ............................2-4 High Idle Speed Adjustment ............................2-4 Fuel system Cleanliness Inspection...........................2-5 Fuel Pump Inspection ..............................2-5 Fuel Filter Inspection..............................2-5 Air Element Removal..............................2-6 Air Element Installation ..............................
  • Page 16: Periodic Maintenance Chart

    Clean and lap valve seating surface P9~P11 • 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: Specifications

    PERIODIC MAINTENANCE 2-3 Specifications Item Standard Fuel System Idle speed: (1) Low idle speed 1550 r/min (rpm) High idle speed 3600 r/min (rpm) Air cleaner: Type Dual stage filtration system Pre-cleaner Foam element Second-stage cleaner Paper element Engine Top End Valve clearance Intake, Exhaust 0.10 ~ 0.15 mm (0.004 ~ 0.006 in.)
  • Page 18: Periodic Maintenance Procedures

    2-4 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Low Idle Speed Adjustment • Disconnect all possilble external loads from the engine. • Start the engine and warm it up thoroughly. Always keep your hands clear of the moving parts. • Move the throttle lever on dash to the idle position, and hold the throttle lever on the carburetor in closed position (turn the governor arm clockwise all the way) and adjust the low idle speed screw [A]...
  • Page 19: Fuel System Cleanliness Inspection

    PERIODIC MAINTENANCE 2-5 Periodic Maintenance Procedures Fuel system Cleanliness Inspection Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 20: Air Element Removal

    2-6 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Element Removal • Push down the latches [A] and remove the air cleaner case [B]. • Remove: Paper Element [A] Foam Element [B] Air Element Installation • Install the element correctly on the air cleaner case. •...
  • Page 21: Air Cleaner Housing (case And Body) Inspection

    PERIODIC MAINTENANCE 2-7 Periodic Maintenance Procedures • Remove the foam element and the paper element. • Clean the foam element [A] in a bath of detergent and water, and let the element air-dry throughly before installing it. • Clean the paper element [A] by tapping it gently on a flat surface to remove dust.
  • Page 22: Valve Clearance Inspection

    2-8 PERIODIC MAINTENANCE 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 Engine Top End chapter). • Place the piston at top dead center (TDC) of the compression stroke turning the crankshaft clockwise facing the flywheel.
  • Page 23: Valve Seat Inspection

    PERIODIC MAINTENANCE 2-9 Periodic Maintenance Procedures Valve Seat Inspection • Remove the valve (see Engine Top End chapter). • Inspect the valve seats for damage. If the seats are warped or distorted beyond reconditioning, replace the cylinder head. • Pitted or worn valve seats can be refaced. Lap the valves to the seats after refacing.
  • Page 24 2-10 PERIODIC MAINTENANCE Periodic Maintenance Procedures Marks Stamped on the Cutter: The marks stamped on the back of the cutter represent the following. Cutter number, selected from 1 to 12 Cutter angle [A] 37.5 Cutter diameter of cutter [B] KS8B Manufactured lot number Operating Procedures: •...
  • Page 25: Lubrication System

    PERIODIC MAINTENANCE 2-11 Periodic Maintenance Procedures • Coat the face of valve sparingly with a fine lapping compound. • Use the vacuum cup tool [A], to grip top of the valve [B]. Rotate the valve in a circular motion to lap the valve to the seat. •...
  • Page 26: Oil Change

    2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Oil Change • Change the oil after first 8 hours of operation. Thereafter change oil every 100 hours. • Start and warm up the engine so the oil will drain easily. Stop the engine. •...
  • Page 27: Electrical System

    PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Electrical System Spark Plug Cleaning and Inspection • Remove the spark plug (See Electrical System chapter). If the plug is oily or has carbon build up on it, clean the plug using a high flash-point solvent and a wire brush or other suitable tool. If the spark plug electrodes are corroded or damaged, or if the insulator is cracked, replace the plug.
  • Page 29 FUEL SYSTEM 3-1 Fuel System Table of Contents Exploded View...................................3-2 Specifications ..................................3-4 Governor Link Mechanism..............................3-5 Control Panel Assembly Removal..........................3-5 Control Panel Assembly Installation...........................3-5 Governor Arm Removal..............................3-5 Governor Arm Installation ............................3-6 Governor Assembly Removal.............................3-6 Governor Assembly Installation..........................3-6 Governor Assembly Inspection ..........................3-7 Governor Shaft Removal............................3-7 Governor Shaft Installation............................3-7 Carburetor ..................................
  • Page 30: Exploded View

    3-2 FUEL SYSTEM Exploded View 1. Pilot Screw T1: 0.7 N m (0.07 kgf m, 6 in lb) 2. Main Jet T2: 2.3 N m (0.23 kgf m, 20 in lb) T3: 4.5 N m (0.46 kgf m, 40 in lb) T4: 5.9 N m (0.60 kgf m, 52 in lb) T5: 6.9 N m (0.70 kgf m, 61 in lb) L: Apply non-permanent locking agent.
  • Page 31 FUEL SYSTEM 3-3 Exploded View T1: 2.0 N m (0.20 kgf m , 18 in lb) T2: 5.9 N m (0.60 kgf m , 52 in lb) T3: 7.8 N m (0.80 kgf m , 69 in lb) O: Apply engine oil.
  • Page 32: Specifications

    3-4 FUEL SYSTEM Specifications Standard Item FH381V FH430V Caburetors Specifications: Make/ type Walbro LMF-2 Walbro LMF-1 Throttle bore diameter 24 mm (0.94 in.) Venturi diameter 14 mm (0.55 in) 16 mm (0.63 in.) Main Jet (MJ) Pilot jet (PJ) Pilot air screw turns out (PS)
  • Page 33: Governor Link Mechanism

    FUEL SYSTEM 3-5 Governor Link Mechanism Control Panel Assembly Removal • Remove: Air Cleaner (see Cleaner Body Removal) Control Panel Mounting Bolts [A] • Remove the control panel assembly [A] while unhooking the governor spring [B] end loop at the panel bracket. •...
  • Page 34: Governor Arm Installation

    3-6 FUEL SYSTEM 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 throttle lever [E] toward each other.
  • Page 35: Governor Assembly Inspection

    FUEL SYSTEM 3-7 Governor Link Mechanism Governor Assembly Inspection Visually check all governor parts for wear and damage. If any parts are worn or damaged, replace them. Governor Shaft Removal • Split the crankcase (see Camshaft/Crankcase chapter). • Unscrew the governor shaft plate screws [A], and pull out the governor shaft [B] outside.
  • Page 36: Carburetor

    3-8 FUEL SYSTEM Carburetor Fuel and Air Flow 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 during moderate to heavy load conditions.
  • Page 37: Low Idle Speed Adjustment

    FUEL SYSTEM 3-9 Carburetor Low Idle Speed Adjustment Refer to Low Idle Speed Adjustment in the Periodic Maintenance Chapter (2nd chapter). High Idle Speed Adjustment Refer to High Idle Speed Adjustment in the Periodic Maintenance Chapter (2nd chapter). High Altitude Operation At high altitude, the standard carburetor air-fuel mixture will be excessively rich.
  • Page 38: Carburetor Removal

    3-10 FUEL SYSTEM Carburetor Carburetor Removal Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well- ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 39: Carburetor Disassembly/assembly

    FUEL SYSTEM 3-11 Carburetor Carburetor Disassembly/Assembly • Refer to the illustration shown for disassembly and assembly. • There are several passage plugs (Ball plugs) in the carburetor body. Do not remove. • Before disassembly, mark the out side of choke valve and throttle valves for assembling them.
  • Page 40: Carburetor Cleaning

    3-12 FUEL SYSTEM Carburetor Carburetor Cleaning Clean the carburetor in a well-ventilated area, and take care that there is no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low flash-point solvents to clean the carburetors.
  • Page 41 FUEL SYSTEM 3-13 Carburetor • With the float [A] assembly installed onto the carburetor body [B], hold the carburetor upside down at eye level. Gently support the float with a finger and bring it down slowly so that the float arm tab [C] just touches the float valve [D].
  • Page 42: Intake Manifold

    3-14 FUEL SYSTEM Intake Manifold Intake Manifold Removal • Remove: Air Cleaner (see Cleaner Body Removal) Engine Upper Cover Carburetor (see Carburetor Removal) • Remove the harness from the clamps [A] on the intake manifold. • Unscrew the manifold mounting bolts [B]. Intake Manifold Installation •...
  • Page 43: Intake Manifold Inspection

    FUEL SYSTEM 3-15 Intake Manifold Intake Manifold Inspection • Inspect the intake manifold for cracks. • Cracks not visible to the eye may be detected by using a metal crack detection system. (Visual color check: commonly found at automotive parts store.) If a crack is present in the intake manifold, replace it.
  • Page 44: Fuel Pump, Fuel Filter

    3-16 FUEL SYSTEM Fuel Pump, Fuel Filter The fuel pump cannot be disassembled, if any damage to the pump is noticed replace it with a new one. Fuel Pump Inspection Refer to Fuel Pump Inspection in the Periodic Maintenance Chapter (2nd chapter).
  • Page 45: Air Cleaner

    FUEL SYSTEM 3-17 Air Cleaner Element Removal Refer to Air Element Removal in the Periodic Maintenance Chapter (2nd chapter). Element Installation Refer to Air Element Instalation in the Periodic Maintenance Chapter (2nd chapter). Element Cleaning and Inspection Refer to Air Element Cleaning and Inspection in the Periodic Mainte- nance Chapter (2nd chapter).
  • Page 47 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View...................................4-2 Cooling Fan..................................4-3 Cooling Fan Removal..............................4-3 Cooling Fan Installation..............................4-3 Cooling Fan Inspection...............................4-3...
  • Page 48: Cooling System

    4-2 COOLING SYSTEM Exploded View T1: 3.4 N m (0.35 kgf m, 30 in lb) T2: 5.9 N m (0.60 kgf m, 52 in lb) T3: 7.8 N m (0.80 kgf m, 69 in lb) T4: 15 N m (1.5 kgf m, 11 ft lb) T5: 56 N m (5.7 kgf m, 41 ft lb)
  • Page 49 COOLING SYSTEM 4-3 Cooling Fan Cooling Fan Removal Refer to Flywheel Removal in Electrical System Chapter. Cooling Fan Installation Refer to Flywheel Installation in 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 cooling fan.
  • Page 51 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View...................................5-2 Specifications ..................................5-4 Cylinder Head..................................5-5 Compression Measurement ............................5-5 Cylinder Head Assembly Removal..........................5-6 Cylinder Head Assembly Installation..........................5-6 Push Rod Removal ..............................5-7 Push Rod Installation ..............................5-7 Push Rod Inspection..............................5-8 Valve Mechanism Removal/Installation........................5-8 Cleaning and Inspection.............................5-9 Rocker Arm Inspection...............................5-9...
  • Page 52: Exploded View

    5-2 ENGINE TOP END Exploded View T1: 5.9 N m (0.60 kgf m, 52 in lb) T2: 6.9 N m (0.70 kgf m, 61 in lb) T3: 22 N m (2.2 kgf m, 16 ft lb) T4: 25 N m (2.6 kgf m, 19 ft lb) T5: 28 N m (2.8 kgf m, 20 ft lb) O: Apply engine oil.
  • Page 53 ENGINE TOP END 5-3 Exploded View T1: 15 N m (1.5 kgf m, 11 ft lb)
  • Page 54: Specifications

    5-4 ENGINE TOP END Specifications Item Service Limit Cylinder Head: Cylinder compression (MIN) [390 kPa (57 psi)] (MIN) Cylinder head warp 0.03 mm (0.001 in.) Valves: Valve head thickness Intake, Exhaust 0.35 mm (0.014 in.) Valve stem runout Intake, Exhaust 0.05 mm (0.002 in.) Valve stem diameter Intake...
  • Page 55: Cylinder Head

    ENGINE TOP END 5-5 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 between the piston and cylinder wall will help seal compression as it does during normal running.
  • Page 56: Cylinder Head Assembly Removal

    5-6 ENGINE TOP END Cylinder Head Cylinder Head Assembly Removal • Remove: Air Cleaner and Carburetor (see Fuel System chapter) Muffler (see Muffler Exhaust Pipe Removal) Intake Manifold (see Fuel System chapter) Spark Plug • Unscrew the rocker cover mounting bolts [A], and remove the cover [B] and gasket.
  • Page 57: Push Rod Removal

    ENGINE TOP END 5-7 Cylinder Head Push Rod Removal • Set each cylinder at T.D.C of power stroke. • Remove the rocker covers (see Cylinder Head Assembly Removal). • Loosen the valve clearance adjusting nuts [A]. • Move the rocker arms [B] to clear the push rod upper ends. •...
  • Page 58: Push Rod Inspection

    5-8 ENGINE TOP END Cylinder Head Push Rod Inspection • Place the rocker arm push rod in V blocks that are as far apart as possible, and set a dial gauge on the rod at a point halfway between the blocks. Turn the rod to measure the runout. The difference between highest and the lowest dial readings is the amount of runout.
  • Page 59: Cleaning And Inspection

    ENGINE TOP END 5-9 Cylinder Head Cleaning and Inspection Refer to Cylinder Head Cleaning and Inspection in the Periodic Maintenance Chapter (2nd chapter). Rocker Arm Inspection • Clean and inspect the rocker arm where it touches the push rod and valve stem.
  • Page 60: Valves

    5-10 ENGINE TOP END Valves Valve Clearance Inspection Refer to Valve Clearance Inspection in the Periodic Maintenance Chapter (2nd chapter). Valve Clearance Adjustment Refer to Valve Clearance Adjustment in the Periodic Maintenance Chapter (2nd chapter). Valve Seat Inspection Refer to Valve Seat Inspection in the Periodic Maintenance Chapter (2nd chapter).
  • Page 61: Valve Spring Inspection

    ENGINE TOP END 5-11 Valves Valve Spring Inspection • Inspect the valve spring for pitting, cracks, rusting, and burns. Replace the spring if necessary. • Measure the free length [A] of the spring. If the measurement is less than the service limit, replace the spring. Valve Spring Free Length Service Limit: 31.5 mm (1.24 in.)
  • Page 62: Cylinder, Piston

    5-12 ENGINE TOP END Cylinder, Piston Piston Removal • Split the crankcase (see Camshaft/Crankshaft chapter). • Remove the camshaft (see Camshaft/Crankshaft chapter). • Turn the crankshaft to expose the connecting rod cap bolts [A]. • Remove the bolts and take off the connecting rod caps [B]. NOTE Note the position of the connecting rod caps for reinstalling the caps.
  • Page 63: Piston Installation

    ENGINE TOP END 5-13 Cylinder, Piston Piston Installation • Install the expander [A] in the piston oil ring groove so that the expander ends [B] touch together, never overlap. • Install the upper and lower steel rails. There is no UP or Down to the rails.
  • Page 64: Piston/cylinder Seizure

    5-14 ENGINE TOP END Cylinder, Piston • Apply engine oil to the piston skirt and the cylinder bore. Using the piston ring compressor grip [A] and the belt [B], lightly tap the top of the piston with a plastic mallet [C] to insert the piston and connecting rod into the cylinder.
  • Page 65: Piston Cleaning

    ENGINE TOP END 5-15 Cylinder, Piston Piston Cleaning • Remove the piston and piston rings (see Piston Removal). CAUTION Never clean the piston head with the engine assembled. Carbon particles will fall between the piston and cylinder, and damage the crankshaft bearings. •...
  • Page 66: Piston Ring End Gap

    5-16 ENGINE TOP END Cylinder, Piston Piston Ring End Gap • Remove the piston rings. • Push each ring (one at a time) in the cylinder bore to a point close to the bottom of the cylinder bore. Use the piston to push it in to be sure it is square. •...
  • Page 67: Piston Diameter

    ENGINE TOP END 5-17 Cylinder, Piston Piston Diameter • Measure the outside diameter [A] of the piston 12.5 mm (0.9 in.) up [B] from the bottom of the piston at a right angle to the direction of the piston pin hole. If the measurement is less than the service limit, replace the piston.
  • Page 68 5-18 ENGINE TOP END Cylinder, Piston Change to a honing stone for finishing, the final bore diameter should be as shown in the table. Be sure the correct stone is used and the stone is not worn. • Clean the cylinder at the top and bottom of the cylinder to remove burns and pieces of the base and head gasket.
  • Page 69: Muffler/exhaust Pipe Installation

    ENGINE TOP END 5-19 Muffler/Exhaust Pipe Installation Muffler/Exhaust Pipe Removal • Loosen the clamp nut [A]. • Remove the bolt [B] on the muffler bracket and take off the muffler. • Unscrew the exhaust pipe flange nuts [A], and remove the exhaust pipe [B] with pipe cover [C].
  • Page 71 LUBRICATION SYSTEM 6-1 Lubrication System Table of Contents Exploded View...................................6-2 Engine Oil Flow Chart...............................6-3 Specifications ..................................6-4 Engine Oil and Oil Filter..............................6-5 Oil Level Inspection..............................6-5 Oil Change ................................. 6-5 Oil Filter Change ................................ 6-5 Pressurized Lubrication System ............................6-6 Oil Pressure Measurement ............................6-6 Oil Pump, Relief Valve ..............................
  • Page 72: Exploded View

    6-2 LUBRICATION SYSTEM Exploded View T1: 3.9 N m (0.40 kgf m, 35 in lb) T2: 5.9 N m (0.60 kgf m, 52 in lb) T3: 6.9 N m (0.70 kgf m, 61 in lb) T4: See the text O: Apply engine oil.
  • Page 73: Specifications

    LUBRICATION SYSTEM 6-3 Specifications...
  • Page 74 6-4 LUBRICATION SYSTEM Specifications Item Standard Engine Oil: Type SF, SG, SH or SJ class Viscosity SAE40, SAE30, SAE10W-30/SAE10W-40, or SAE5W-20 Capacity [When filter is not removed] 1.5 L (1.6 US qt) [When filter is removed] 1.7 L (1.8 US qt) Level Operating range (grid area) on dipstick Oil Pressure...
  • Page 75: Engine Oil And Oil Filter

    LUBRICATION SYSTEM 6-5 Engine Oil and Oil Filter CAUTION Engine operation with insufficient, deteriorated, or contami- nated engine oil will cause accelerated wear and may result in engine seizure and accident. Before starting the engine for the first time, add oil: The engine is shipped dry.
  • Page 76: Pressurized Lubrication System

    6-6 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, and return to the crankcase.
  • Page 77: Oil Pump, Relief Valve

    LUBRICATION SYSTEM 6-7 Oil Pump, Relief Valve Oil Pump, Relief Valve Removal • Remove the crankcase cover (see Camshaft/Crankshaft chapter). • Unscrew the mounting bolts and remove the oil pump parts assembly (pump gear, pump cover plate, pump shaft, pins and rotors). •...
  • Page 78 6-8 LUBRICATION SYSTEM Oil Pump, Relief Valve • Measure the inside diameter [A] of the pump housing with an inside micrometer at several points. If the inside diameter is more than the service limit, replace the crankcase cover. Pump Housing Inside Diameter Service Limit: 40.801 mm (1.6063 in.) •...
  • Page 79: Oil Screen

    LUBRICATION SYSTEM 6-9 Oil Screen Oil Screen Removal • Remove the crankcase cover (see Camshaft/Crankcase chapter). • Unscrew the mounting bolts [A] and remove the oil pump parts assembly. • Remove the oil screen [B] Oil Screen Installation • Clean the oil screen thoroughly whenever it is removed for any reason. •...
  • Page 81 CAMSHAFT/CRANKSHAFT 7-1 Camshaft/Crankshaft Table of Contents Exploded View...................................7-2 Specifications ..................................7-3 Crankcase ..................................7-4 Crankcase Cover Removal............................7-4 Crankcase Cover Installation ............................. 7-4 Inspection ................................... 7-5 Cleaning ..................................7-5 Breather.....................................7-6 Breather Chamber Cover Removal ...........................7-7 Breather Chamber Cover Installation ........................7-7 Camshaft, Tappet................................7-8 Camshaft, Tappet Removal............................7-8 Camshaft, Tappet Installation.............................7-8 Camshaft Disassembly...............................7-9...
  • Page 82: Exploded View

    7-2 CAMSHAFT/CRANKSHAFT Exploded View T1: 5.9 N m (0.60 kgf m, 52 in lb) T2: 25 N m (2.6 kgf m, 19 ft lb) T3: See Engine Top End chapter. O: Apply engine oil. G: Apply grease. M: Apply molybdenum disulfide grease. SS: Apply silicone sealant.
  • Page 83: Specifications

    PTO side 34.90 mm (1.374 in.) Flywheel side 34.94 mm (1.376 in.) Crankcase: PTO shaft bearing inside diameter Crankcase Cover 35.15 mm (1.384 in.) Crankshaft journal bearing inside diameter Crankcase 35.15 mm (1.384 in.) Sealant - Kawasaki Bond (Silicone Sealant): 56019–120...
  • Page 84: Crankcase

    7-4 CAMSHAFT/CRANKSHAFT Crankcase Crankcase Cover Removal • Set the engine on a clean surface while parts are being removed. • Drain the oil (see Lubrication System chapter). • Remove: Exhaust Pipe and Muffler (see Engine Top End chapter) Control Panel (see Fuel System chapter) Governor Arm (see Fuel System chapter) •...
  • Page 85: Inspection

    CAMSHAFT/CRANKSHAFT 7-5 Crankcase • Check to see that the crankcase dowel pins [A] are in place on the crankcase. • Install the gasket on the crankcase. • Install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence shown. Torque - Crankcase Cover Bolts: 25 N m (2.6 kgf m, 19.0 ft lb) Do not turn one bolt down completely before the others, as it may...
  • Page 86: Breather

    7-6 CAMSHAFT/CRANKSHAFT Breather The function of the breather is to create a vacuum in the crankcase which prevents oil from being forced out of the engine through the piston rings, oil seals or gaskets. A sealed-type crankcase emission control system is used to eliminate blow-by gases.
  • Page 87: Breather Chamber Cover Removal

    Remove the bolts [A] and breather chamber cover [B]. Breather Chamber Cover Installation • Apply sealant [A] to the mating surface of the crankcase. Sealant - Kawasaki Bond (Silicone Sealant) : 56019-120 • Install a new gasket and the breather chamber cover, and tighten the bolts. Torque -...
  • Page 88: Camshaft, Tappet

    7-8 CAMSHAFT/CRANKSHAFT Camshaft, Tappet Camshaft, Tappet Removal • Set the engine on a clean surface while parts are being removed. • Drain the oil (see Lubrication System chapter). • Remove: Muffler (see Engine Top End chapter) Throttle Control Panel (see Fuel System chapter) Carburetor (see Fuel System chapter) Intake Manifold (see Fuel System chapter) Crankcase Cover (see Crankcase Cover Removal)
  • Page 89: Camshaft Disassembly

    CAMSHAFT/CRANKSHAFT 7-9 Camshaft, Tappet Camshaft Disassembly • Remove the governor assembly (see Fuel System chapter). • Remove: Spring [A] Do not remove the ACR (automatic compression release) weight [B]. Camshaft Assembly • Install the governor assembly (see Fuel System chapter). •...
  • Page 90 7-10 CAMSHAFT/CRANKSHAFT Camshaft, Tappet • Measure the inside diameter [A] of the camshaft bearing on the crankcase at several points. This bearing is not replaceable. Replace the crankcase if the inside diameter is more than the service limit. Camshaft Bearing Inside Diameter (Crankcase) Service Limit: 16.136 mm (0.6352 in.) •...
  • Page 91: Crankshaft, Connecting Rod

    CAMSHAFT/CRANKSHAFT 7-11 Crankshaft, Connecting Rod Connecting Rod Removal • Remove: Piston (see Engine Top End chapter) Connecting Rod Installation • Install: Piston (see Engine Top End chapter) Crankshaft Removal • Set the engine on a clean surface while parts are being removed. •...
  • Page 92: Connecting Rod Big End/crankpin Width Wear

    7-12 CAMSHAFT/CRANKSHAFT Crankshaft, Connecting Rod • Measure connection rod twist. With the big-end arbor still on the V blocks, hold the connection rod horizontally and measure the amount that the small end arbor varies from being parallel with the surface plate over a 100 mm length of the arbor to determine the amount of connecting rod twist.
  • Page 93: Crankshaft Runout

    CAMSHAFT/CRANKSHAFT 7-13 Crankshaft, Connecting Rod Crankshaft Runout • Measure the crankshaft runout. Set the crankshaft in a flywheel alignment jig or on V blocks gauge. Set a dial gauge against both bearing journals. Turn the crankshaft slowly to measure the runout. The difference between the highest and lowest dial gauge readings (TIR) is the amount of runout.
  • Page 95 ELECTRICAL SYSTEM 8-1 Electrical System Table of Contents Exploded View...................................8-2 Specifications ..................................8-4 Wiring Diagram ................................8-5 Precautions ..................................8-8 Charging, Ignition System..............................8-9 Flywheel, Stator Coil Removal...........................8-9 Flywheel, Stator Coil Installation..........................8-10 Charging System Operational Inspection.........................8-11 Stator Coil Resistance..............................8-12 Unregulated Stator Output ............................8-12 Regulator Removal..............................8-12 Regulator Installation..............................8-12 Regulator Resistance...............................8-13...
  • Page 96: Exploded View

    8-2 ELECTRICAL SYSTEM Exploded View T1: 3.4 N m (0.35 kgf m, 30 in lb) T2: 5.9 N m (0.60 kgf m, 52 in lb) T3: 7.8 N m (0.80 kgf m, 69 in lb) T4: 22 N m (2.2 kgf m, 16 ft lb) T5: 56 N m (5.7 kgf m, 41 ft lb)
  • Page 97 ELECTRICAL SYSTEM 8-3 Exploded View T1: 3.9 N m (0.40 kgf m, 35 in lb) T2: 5.9 N m (0.60 kgf m, 52 in lb) T3: 7.8 N m (0.80 kgf m, 69 in lb) T4: 15 N m (1.5 kgf m, 11 ft lb) G: Apply grease.
  • Page 98: Specifications

    8-4 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Charging System: Regulated output voltage 14.1 V DC/3600 rpm 15 V DC/3600 rpm Alternator stator coil resistance in the text – – – Unregulated stator output 28.4 V AC/3000 rpm 26V AC/3000 rpm Regulator resistance in the text Ignition System:...
  • Page 99: Wiring Diagram

    ELECTRICAL SYSTEM 8-5 Wiring Diagram...
  • Page 100 8-6 ELECTRICAL SYSTEM Wiring Diagram...
  • Page 101 ELECTRICAL SYSTEM 8-7 Wiring Diagram...
  • Page 102: Precautions

    8-8 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below. Do not reverse the battery lead connections. This will burn out the diodes in the electrical parts. Always check battery condition before condemning other parts of an electrical system.
  • Page 103: Charging, Ignition System

    ELECTRICAL SYSTEM 8-9 Charging, Ignition System Flywheel, Stator Coil Removal • Remove: Recoil Starter (see Recoil Starter Removal) Nuts [A] and Guard [B] Screws [C] and Screen [D] Spacer [E] • Loosen the fan housing bolts [A] and remove the fan housing [B]. •...
  • Page 104: Flywheel, Stator Coil Installation

    8-10 ELECTRICAL SYSTEM Charging, Ignition System • Remove: Woodruff Key [A] Stator Coil Lead Connector [B] Stator Coil Screw [C] Stator Coil [D] Flywheel, Stator Coil Installation • Install the stator coil and tighten the screws. Torque - Stator Coil Screws: 3.4 N m (0.35 kgf m, 30 in lb) •...
  • Page 105: Charging System Operational Inspection

    ELECTRICAL SYSTEM 8-11 Charging, Ignition System • Install the fan housing and tighten the bolts. Torque - Fan housing Bolts: 5.9 N m (0.60 kgf m, 52 in lb) • Install: Recoil Starter (see Recoil Starter Installation) • Install: Spacer [A] Screen [B] Position three sets [C] of screen notches around the fan blades.
  • Page 106: Stator Coil Resistance

    8-12 ELECTRICAL SYSTEM Charging, Ignition System Stator Coil Resistance • Disconnect the connector [A]. • Measure the stator coil resistance. (Electric Starter Model) Connect an ohmmeter between stator pins [B]. Stator Coil Resistance (Electric Starter Model) 0.01 to 0.1 (Recoil Starter Model with Electric Clutch) Connect an ohmmeter between stator pin and engine-body.
  • Page 107: Regulator Resistance

    ELECTRICAL SYSTEM 8-13 Charging, Ignition System Regulator Resistance • Set the KAWASAKI Hand Tester selector switch to the R position. • Connect the test leads to the points shown on the chart and read the resistance. There are two(2) types of Regulator on FH engines as follows: (with out Charging Monitor Type …3 Blades)
  • Page 108 8-14 ELECTRICAL SYSTEM Charging, Ignition System This engine ignition is controlled by a solid state ignition assembly and requires no periodic maintenance except for the spark plugs. The system consists of the following: Inductive Ignition Assemblies Permanent Magnet Flywheel Spark Plugs Stop Switch Co: Core (Lamination) R1: Control Resistor...
  • Page 109: Ignition Coil Removal

    ELECTRICAL SYSTEM 8-15 Charging, Ignition System Ignition Coil Removal • Remove: Fan Housing (see Flywheel, Stator Coil Removal) Spark Plug Cap [A] Stop Switch Lead Connector [B] Bolts [C] Ignition Coil [D] Ignition Coil Installation • Install ignition coil on crankcase so that the stop switch lead connector [B] face the screen, and tighten bolt (1) first, then tighten bolt (2).
  • Page 110: Ignition Coil Inspection

    Ignition Coil Winding Resistance CAUTION Use only Tester 57001–1394 with new battery at room tempera- ture 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 111: Starter System

    ELECTRICAL SYSTEM 8-17 Starter System Starter Motor Removal • Remove the mounting bolts [A] and pull the starter motor [B] from the engine. Starter Motor Installation • Clean the starter motor and engine mounting flanges to ensure good electrical contact and tighten the mounting bolts. Torque - Starter Motor Mounting Bolts: 15 N m (1.5 kgf m, 11.0 ft lb) Starter Motor Disassembly...
  • Page 112: Starter Motor Assembly

    8-18 ELECTRICAL SYSTEM Starter System Starter Motor Assembly • Assembly is the reverse of disassembly. • Apply a small amount of grease to the armature shaft [A]. • Press the springs and holding the brush leads with suitable clips. • Fit the brush assembly [A] into the armature [B].
  • Page 113: Armature Inspection

    ELECTRICAL SYSTEM 8-19 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. • Measure the depth of the grooves between the commutator segments. If the grooves are shallower than the specified limit, replace the armature with a new one.
  • Page 114: Pinion Clutch Inspection

    8-20 ELECTRICAL SYSTEM Starter System Pinion Clutch Inspection • Turn the pinion gear by hand. The pinion gear should turn clockwise freely. If the pinion clutch does not operate as it should, or if it makes noise, replace the pinion clutch. Recoil Starter Removal •...
  • Page 115 ELECTRICAL SYSTEM 8-21 Starter System • Remove: Screw [A] Washer [B] Retainer [C] Center Spring [D] Washer [E] Pawls [F] Return Springs [G] When removing the reel [A], be careful that the recoil spring [B] under the reel does not fly loose and cause injury. The spring is under great pressure.
  • Page 116: Recoil Starter Assembly

    8-22 ELECTRICAL SYSTEM Starter System Recoil Starter Assembly Wear gloves during the recoil spring installation to avoid injury. The recoil spring must be assembled with great pressure. • Lightly grease the recoil spring. • Set the recoil spring into the spring cassette. •...
  • Page 117 ELECTRICAL SYSTEM 8-23 Starter System • While holding the reel to keep it from unwinding, feed the end of the rope through the hole in the case. • Clip the rope as shown to hold it. • Install the handle [A], and secure it with a knot [B]. •...
  • Page 119 TROUBLESHOOTING 9-1 Troubleshooting Table of Contents Engine Troubleshooting Guide............................9-2 Starter Motor Troubleshooting Guide..........................9-6...
  • Page 120: Troubleshooting

    9-2 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 121 TROUBLESHOOTING 9-3 Engine Troubleshooting Guide...
  • Page 122 9-4 TROUBLESHOOTING Engine Troubleshooting Guide...
  • Page 123 TROUBLESHOOTING 9-5 Engine Troubleshooting Guide...
  • Page 124 9-6 TROUBLESHOOTING Starter Motor Troubleshooting Guide 1. Disconnect spark plug caps from the spark plugs. 2. Turn engine switch to “START” position and check condition. Engine may be cranked in this test. Do not touch any rotating parts of engine and equipment during test. CAUTION If starter does not stop by engine switch “OFF”, disconnect negative (−) lead from battery as soon as possible.

This manual is also suitable for:

Fh430v

Comments to this Manuals

Symbols: 0
Latest comments: