Download  Print this page

Kawasaki FE120 Service Manual

4–stroke air-cooled gasoline engine.
Hide thumbs

Advertisement

4–stroke air-cooled 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 Group/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.
© Kawasaki Heavy Industries, Ltd., 2000
FE120 FE170
FE250 FE290
FE350 FE400
First Edition (1) : Sep. 1, 2000 (K)

Advertisement

Table of Contents

   Also See for Kawasaki FE120

   Related Manuals for Kawasaki FE120

   Summary of Contents for Kawasaki FE120

  • Page 1 Quality Assurance Department/Consumer Products & Machinery Group/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...
  • Page 3: Emission Control Information

    EMISSION CONTROL INFORMATION To protect the environment in which we live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board.
  • Page 4: How To Use This Manual

    Be alert for problems and non-scheduled maintenance. This manual contains four more symbols (in addition to • Use proper tools and genuine Kawasaki engine parts. WARNING and CAUTION) which will help you distinguish Genuine parts provided as spare parts are listed in the different types of information.
  • Page 5: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing.................................1-2 General Specifications ............................... 1-4 Periodic Maintenance Chart...............................1-6 Special Tools ..................................1-7 Exploded View..................................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: General Specifications

    1-4 GENERAL INFORMATION General Specifications Item FE120 FE170 Type D Type G Type D Type G Dimensions: 11.46 13.43 19.54 11.81 13.94 14.57 Dry Weight 14.5 16.8 Engine: Type of engine Air cooled, 4-stroke, OHV, Single cylinder, Gasoline engine Number of Cylinder...
  • Page 9 GENERAL INFORMATION 1-5 General Specifications Item FE250 FE290 FE350 FE400 Type D Type G Type D Type G Type D Type G Type D Type G Dimensions: 344.5 13.56 15.55 17.01 14.29 16.06 17.36 14.88 16.61 17.87 14.88 16.61 18.07 Dry Weight With recoil starter 26.8...
  • Page 10: Periodic Maintenance Chart

    NOTE: The service intervals indicated are to be used as a guide. Service should be performed more frequently as necessary by operating condition. : Service more frequently under dusty conditions. K: Have an authorized Kawasaki engine dealer perform those services.
  • Page 11: Special Tools

    Compression Gauge: 57001–221 Piston Ring Compression Grip: 57001–1095 Piston Ring Compression Belt, 50– 67: 57001–1096 Hand Tester: 57001–1394 Piston Ring Compression Belt, 67– 79: 57001–1097 Kawasaki Bond (Silicone Sealand): 56019–120 Piston RIng Pliers: 57001–115 Piston Ring Compression Belt, 80– 91: 57001–1320...
  • Page 12: Exploded View

    1-8 GENERAL INFORMATION Exploded View FE120...
  • Page 13 GENERAL INFORMATION 1-9 Exploded View FE170...
  • Page 14 1-10 GENERAL INFORMATION Exploded View FE250...
  • Page 15 GENERAL INFORMATION 1-11 Exploded View FE290...
  • Page 16 1-12 GENERAL INFORMATION Exploded View FE350...
  • Page 17 SERVICE DATA 2-1 Service Data Table of Contents Service Specifications ................................2-2 Adjustment Specifications ..............................2-8 Tightening Torque Specifications ............................2-9 Wiring Diagram.................................2-10 Troubleshooting ................................2-12 Starter Motor Troubleshooting and Actions.......................2-17 Disassembly Sequence (FE120, 170)..........................2-18 Disassembly Sequence (FE250, 290, 350, 400) ......................2-19...
  • Page 18: Service Specifications

    2-2 SERVICE DATA Service Specifications Service Limit (mm) Item FE120 FE170 FE250 Type D Type G Type D Type G Type D Type G Compression (minimum) � � with Recoil Starter 290 kPa (3 kg/cm , 42 psi) � �...
  • Page 19 SERVICE DATA 2-3 Service Specifications Service Limit (mm) Item FE120 FE170 FE250 Type D Type G Type D Type G Type D Type G Connecting Rod Connecting Rod Big End Bore (maximum) 26.052 29.052 34.067 (1.0257 in) (1.1438 in) (1.3412 in) Connecting Rod Small End Bore (maximum) 14.042...
  • Page 20 2-4 SERVICE DATA Service Specifications Service Limit (mm) Item FE290 FE350 FE400 Type D Type G Type D Type G Type D Type G Compression (minimum) � � with Recoil Starter 290 kPa (3 kg/cm , 42 psi) � � with Electric Starter 390 kPa (4 kg/cm , 57 psi)
  • Page 21 SERVICE DATA 2-5 Service Specifications Service Limit (mm) Item FE290 FE350 FE400 Type D Type G Type D Type G Type D Type G Axial Play (maximum) – – – 0.35 0.35 0.35 0.06 0.35 (0.013 in) (0.013 in) (0.013 in) (0.024) (0.013 in) (standard:...
  • Page 22 2-6 SERVICE DATA Service Specifications Service Limit (mm) Item FE120 FE170 FE250 Type D Type G Type D Type G Type D Type G Piston Ring Piston Ring Thickness (minimum) � Top, Second 1.42 (0.056 in) 1.44 (0.057 in) Piston Ring End Gap (maximum) �...
  • Page 23 SERVICE DATA 2-7 Service Specifications Service Limit (mm) Item FE290 FE350 FE400 Type D Type G Type D Type G Type D Type G Piston Ring Piston Ring Thickness (minimum) � � Top, Second 1.44 (0.057 in) Piston Ring End Gap (maximum) �...
  • Page 24: Adjustment Specifications

    2-8 SERVICE DATA Adjustment Specifications Adjustment Specifications Item FE350 FE120 FE170 FE250 FE290 FE400 Idle Speed Setting 1600 rpm 1300 rpm (crankshaft) No-Load Maximum Speed Setting 4000 rpm (crankshaft) Valve Clearance: Adjustment Intake, Exhaust 0.12 mm (0.0047 in) unnecessary (clearance on cold engine) Spark Plug Electrode Gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
  • Page 25: Tightening Torque Specifications

    SERVICE DATA 2-9 Tightening Torque Specifications Tightening Torque Specifications Unit: N m (kg m, ft Tightening Torque Tightening Location FE350 FE120 FE170 FE250 FE290 FE400 Cylinder Head Bolts 25 (2.5, 18) Connecting Rod Bolts (Apply Oil to Threadss before Tightening) (1.2, 8.9 in...
  • Page 26: Wiring Diagram

    2-10 SERVICE DATA Wiring Diagram Ignition Coil/Ignition Separate Type...
  • Page 27 SERVICE DATA 2-11 Wiring Diagram Ignition Coil/Igniter Integrated Type...
  • Page 28: Troubleshooting

    2-12 SERVICE DATA Troubleshooting If the engine malfunctions, first check whether th engine has been operated correctly. Then, systematically carry out the troubleshooting procedure starting with simple items. This troubleshooting chart lists typical malfunctions. Do not unnecessarily disassemble any parts before the cause of the problem is identified.
  • Page 29 SERVICE DATA 2-13 Troubleshooting...
  • Page 30 2-14 SERVICE DATA Troubleshooting...
  • Page 31 SERVICE DATA 2-15 Troubleshooting...
  • Page 32 2-16 SERVICE DATA Troubleshooting...
  • Page 33: Starter Motor Troubleshooting And Actions

    SERVICE DATA 2-17 Troubleshooting Starter Motor Troubleshooting and Actions • Remove spark plug cap and ground the high-tension lead terminal. • Perform an inspection by turning the key switch to the START position. CAUTION Do not touch the parts or accessories other than the starter motor when troubleshooting the starter motor.
  • Page 34: Disassembly Sequence (fe120, 170)

    M6 nut M6 bolt Fan Housing Disconnect wire to stop switch. M6 bolt (FE120 = 4) Electrical: • Ignition Coil * FE120 uses M6 bolts. M5 bolt • Flywheel M14 nut Cylinder Head: • Rocker Case M6 bolt • Cylinder Head...
  • Page 35: Disassembly Sequence (fe250, 290, 350, 400)

    SERVICE DATA 2-19 Disassembly Sequence (FE250, 290, 350, 400) Bolt to be removed for tool Disassembly Area Precaution Name Quantity Drain Plug Warm up engine and drain oil. 14 across Fuel Tap, Fuel Tank Drain fuel before disassembly. M6 bolt (tap) M6 bolt (tank) Spark Plug 21 across...
  • Page 37 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-1 Disassembly, Reassembly, Inspection, and Maintenance Table of Contents Carburetor..............3-2 Valve Disassembly and Reassembly....3-32 Construction and Function ........3-2 Valve Guide Inspection........3-33 Disassembly, Cleaning, and Reassembly Precau­ Valve Inspection ..........3-33 tions ..............3-3 Valve Spring Inspection........3-34 Adjustment............3-4 Valve Seat Inspection and Lapping....
  • Page 38: Carburetor

    3-2 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE Carburetor Construction and Function The function of a carburetor is to mix fuel and air by applying the principle of an atomizer, thus creating an appropriate air-fuel mixture in accordance with load fluctuations. The major functions of a carburetor consist of the following four systems.
  • Page 39: Disassembly, Cleaning, And Reassembly Precautions

    DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-3 Carburetor An optimal fuel level is prescribed at the time the carburetor is designed. Along with the fluctuations in the fuel level, the float moves up and down in order to open and close the float valve. The flow of fuel into the float chamber is enabled or stopped in this manner in order to maintain the fuel level at the prescribed level.
  • Page 40: Adjustment

    3-4 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE Carburetor • Check how the float valve spring is fitted. Make sure that the first coil of the float valve spring is completely wrapped in both spring grooves that are provided at the two ear-shaped protrusions on the float valve body.
  • Page 41 Release the throttle lever of the carburetor to free the speed adjustment lever. Turn the low-speed set screw on the control panel to set the engine speed to the minimum no-load speed. Minimum No-Load Speed (idling) Setting (crankshaft speed) FE120, 170: 1600 rpm FE250, 290, 350, 400: 1300 rpm NOTE �...
  • Page 42: Carburetor With Fuel Cutoff Valve

    3-6 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE Carburetor Carburetor with Fuel Cutoff Valve To prevent after-burns that occur in the form of combustion in the muffler when the engine is stopped, the float chamber of this carburetor is provided with a solenoid-actuated fuel cutoff valve. When the engine switch is turned to the STOP position, the solenoid operates the fuel shut off solenoid valve to stop the flow of the fuel that is supplied to the main jet.
  • Page 43: Governor Mechanism

    DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-7 Governor Mechanism Governor Operating Mechanism Connected to the throttle lever on the carburetor via a link rod, the governor operates automatically in accordance with load fluctuations in order to maintain a constant engine speed. The governor relies on centrifugal force for its operation.
  • Page 44: Governor Gear Assembly Installation

    Direction of Rotation for Tightening the Governor Arm and the Governor Shaft FE120, 170: Clockwise FE250, 290, 350, 400: Counterclockwise 1.
  • Page 45 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-9 Governor Mechanism A: Governor Arm B: Throttle Valve C: Governor Shaft D: Clamp Nut E: Pin...
  • Page 46: Air Cleaner

    Otherwise, wash it in a soap solution by shaking it, rinse it in water, and allow it to air dry. If the element is extremely dirty, replace it with a new one. Type A: for FE120, 170 Type B: for FE250, 290, 350, 400 1. Sponge Element...
  • Page 47: Cooling System

    DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-11 Cooling System All the cooling fans of the FE series engines are the separate type that can be separated from the flywheel. FE290 type: NOTE � On the engine produced before May 1996, the flywheel and the cooling fan are integrated and cannot be disassembled.
  • Page 48: Fuel Tank And Filter

    3-12 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE Fuel Tank and Filter • Place an appropriate container under the fuel filter to catch the fuel. Remove the filter pot, turn the fuel tap ON, and completely drain the fuel from the fuel tank and the fuel line. If the drained fuel contains dust or water, the fuel line from the fuel filter to the carburetor must be inspected and cleaned.
  • Page 49: Ignition System

    DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-13 Ignition System Description of Function The ignition mechanism is the transistorized type and consists of the following parts: Ignition Coil Igniter Flywheel (with permanent magnet) These components do not contain mechanical contact parts and do not require regular inspection.
  • Page 50: Spark Inspection

    3-14 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE Ignition System Automatic Ignition Advance Device This device enables the engine to achieve appropriate ignition timing in all speed ranges. The ignition timing must be retarded slightly when the engine is started and at the low- to medium-speed range. On the other hand, the ignition timing must be advanced in the high-speed range in order to generate the sparks early on, because the intervals of the air-fuel mixture ignition and expansion are shorter.
  • Page 51: Ignition Coil Inspection

    DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-15 Ignition System Ignition Coil Inspection Spark Characteristics Measurement • Connect the ignition coil to a coil tester to measure its spark characteristics. Follow the measurement instructions provided by the tester manufacturer for the proper measurement procedure. (For testing purposes, remove the plug cap from the ignition coil.) Ignition Coil Spark Characteristics (three-wire spark gap) Standard:...
  • Page 52: Igniter Inspection

    3-16 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE Ignition System Igniter Inspection Measure the internal resistance of the igniter. Individual Igniter Inspection • To test the individual igniter shown in the diagram on the right, set the � measurement range of the hand tester to R and measure the resistance.
  • Page 53: Flywheel Disassembly And Reassembly

    DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-17 Ignition System Controller (with Warning Light) Measurement � • Set the measurement range of the hand tester to R measure the resistance at the areas given in the table below. � Controller (without ground) Resistance Tester (–) Negative Tester Positive (+) Terminal Terminal...
  • Page 54: Ignition Coil Reassembly (air Gap Adjustment).3-18

    Ignition Coil Air Gap Standard: 0.3 mm (0.012 in) Adjustable Range: 0.25 ~ 0.4 mm (0.010 ~ 0.016 in) Ignition Coil Retaining Bolt Specified Tightening Torque FE120 (M6 bolt): 6.0 N m (0.6 kg m, 53 in lb) FE170, 250, 290, 350, 400: 3.5 N...
  • Page 55: Charging System

    DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-19 Charging System The state of charge of the battery must be determined by measuring the terminal voltage of the individual battery. Individual Battery’s Terminal Voltage Standard: 12 V If the terminal voltage is below the standard, the battery must be recharged.
  • Page 56: Regulator Inspection

    3-20 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE Charging System Regulator Inspection • Disconnect the connector from the regulator. � • Set the measurement range of the hand tester to R measure the resistance at the areas given in the table below. •...
  • Page 57: Starter System

    DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-21 Starter System Starter Motor Construction An FE series engine comes with a Bendix type or shift-lever type starter motor. The electrical circuit of a starter motor consists of a key switch (engine switch), solenoid (or solenoid switch on the Bendix type), battery, and starter motor.
  • Page 58: Solenoid (starter Motor) Wiring Inspection

    3-22 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE Starter System 1. Snap Ring 2. Collar 3. Spring 4. Clutch Assembly 5. Nut 6. Spring Washer 7. Bolt 8. Rear Cover 9. Washer 10. Brush Holder 11. Brush Spring 12. Brush 13. Yoke Assembly 14.
  • Page 59: Starter Motor Inspection

    DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-23 Starter System • Connect lead [B] to terminal [C]. Set the measurement range of the � tester to R , and connect it to the two terminals on the solenoid. Turn the key switch to the START position to read the tester. �...
  • Page 60 3-24 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE Starter System Commutator Diameter Measurement Measure the diameter of the commutator at several areas. If the diameter is smaller than the service limit, replace the armature. Commutator Diameter Service Limit (minimum) Sift Lever Type: P/N 21163-2089, 2095 27 mm (1.06 in) Bendix Type:...
  • Page 61: Recoil Starter

    NOTE � On the FE120, 170, 250, 290, 350, and 400 also, handle the recoil spring carefully to prevent it from jumping out, and do not reverse the winding direction of the recoil spring and the rope.
  • Page 62: Cylinder Head

    This will allow the rocker arm to move freely (except FE350 and 400). On the FE120, 170, and 250, loosen the lock nut on the rocker arm pivot to remove the lock nut and the rocker arm pivot. Then, remove the rocker arm.
  • Page 63: Cleaning And Inspection

    DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-27 Cylinder Head Cleaning and Inspection • Inspect the cylinder head for the presence of any cracks or missing fins. Replace the cylinder head if any of those conditions exist. • Clean the carbon deposits off the combustion chamber and the exhaust port, and wash the cylinder head in a cleaning solvent.
  • Page 64: Valve System

    3-28 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE Valve System Hydraulic Lash Adjuster (HLA) The FE350 and 400 are equipped with a Hydraulic Lash Adjuster (HLA) to automatically adjust the valve train to zero clearance through hydraulic means. Purpose of the HLA The HLA hydraulically adjusts the valve train to zero clearance by automatically absorbing the changes in the clearance that are created through thermal expansion or wear.
  • Page 65 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-29 Valve System HLA Construction and Operation • When the cam pushes the HLA upward, the oil in the high-pressure chamber [H] tries to flow back to the oil pool [I] of the plunger [G] by passing through the passage [M], but because the check ball [E] closes the passage [M], the oil cannot flow back and it causes the hydraulic pressure in the high-pressure chamber [H] to rise.
  • Page 66 3-30 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE Valve System HLA Removal CAUTION Always keep the HLA upright, with the end of the HLA on which the snap ring is visible facing up (socket "A" faces up). If it is placed on its side or upside down, the oil that is sealed in the high-pressure chamber [B] could leak out, disabling the HLA function.
  • Page 67: Valve Clearance Inspection And Adjustment

    • Loosen the lock nut. Turn the rocker arm pivot in or out to attain the specified clearance. (FE120, 170, 250) On the FE290, use a pair of pliers to hold the adjustment bolt, and then loosen the lock nut. Turn the adjustment bolt in or out to attain the specified clearance.
  • Page 68: Automatic Compression Release (acr) Device Inspection

    ACR that is provided on the camshaft is faulty. (Refer to the section on Camshaft Inspection.) Valve Lift Height Service Limit (minimum) by ACR - for Exhaust FE120, 170, 250, 290: 0.6 mm (0.024 in) FE350, 400: 1.0 mm (0.039 in)
  • Page 69: Valve Guide Inspection

    Inspect the valve for any depression in its contact surface [A], and whether the thickness of the valve head [B] is below the service limit. Valve Head Thickness Service Limit (minimum) - for both Intake and Exhaust FE120, 170: 0.5 mm (0.020 in) FE250, 290, 350, 400: 0.6 mm (0.024 in) If the valve head is smaller than the service limit given above, replace the valve with a new one.
  • Page 70: Valve Spring Inspection

    If the measured value is smaller than the service limit, replace the valve with a new one. Valve Stem Diameter Service Limit (minimum) Intake Valve Exhaust Valve FE120, 170: 5.430 mm (0.2138 in) 5.415 mm (0.2132 in) FE250: 5.930 mm (0.2335 in) 5.915 mm (0.2329 in)
  • Page 71: Valve Seat Inspection And Lapping

    DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-35 Valve System Valve Seat Inspection and Lapping A prerequisite for inspecting the valve seat contact is that the valve guide and the valve stem are normal. • Apply a thin layer of fine lapping compound on the contact surface of the valve.
  • Page 72: Rocker Arm And Rocker Shaft

    If the contact width is inadequate, cut the seat again and lap the valve. Rocker Arm and Rocker Shaft For FE120, 170, 250 • If abnormal wear is present on the ball surface of the rocker arm, or the surface that comes in contact with the valve stem and the pushrod, replace the rocker arm with a new one.
  • Page 73: Piston And Connecting Rod

    DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-37 Piston and Connecting Rod Disassembly • Drain the engine oil into an appropriate container. • Remove the retaining bolts from the crankcase cover. Using a wooden or a plastic mallet, gently tap on the crankcase cover at the area where the cover is fastened to the crankcase, and remove the crankcase cover.
  • Page 74 3-38 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE Piston and Connecting Rod For FE120, 170, 250, 350, 400 • On type D, face the "R" mark on the top of the piston towards the side of the connecting rod marked "MADE IN JAPAN".
  • Page 75: Piston Inspection

    A: Piston B: Connecting Rod C: Arrow For FE120, 170, 250, 350, 400 • On both types D and G, the "MADE IN JAPAN" side of the connecting rod must face the magneto.
  • Page 76: Piston Pin Inspection

    Using a micrometer, measure the thickness of the piston ring in several places. Piston Ring Thickness Service Limit (minimum) - for both Top and Second Rings FE120, 170: 1.42 mm (0.056 in) FE250, 290, 350, 400: 1.44 mm (0.057 in) If the measured value is smaller than the service limit, replace the piston rings as a set.
  • Page 77: Connecting Rod Inspection

    • Using an inside micrometer, measure the bore of the bearing area of the small end in several places. Connecting Rod Small End Bearing Area Bore Service Limit (maximum) FE120: 14.042 mm (0.5528 in) FE170: 16.047 mm (0.6318 in) FE250: 18.051 mm (0.7107 in)
  • Page 78 3-42 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE Piston and Connecting Rod A: Dial Gauge B: V Block...
  • Page 79: Cylinder Block And Crankcase Cover

    Using a cylinder gauge, measure the cylinder bore in the longitudinal and latitudinal directions at the locations given in the diagram on the right. Cylinder Bore Service Limit (maximum) FE120: 60.067 mm (2.3648 in) FE170: 66.067 mm (2.6011 in) FE250: 76.067 mm (2.9948 in)
  • Page 80: Ball Bearing

    Ball Bearing • The table below lists the areas in which ball bearings are used. An empty area signifies that the case acts directly as a plain bearing. Ball Bearing Areas and Nominal Numbers FE120 FE170 FE250 FE290 FE350, 400...
  • Page 81: Oil Seal

    Plain Bearing Area Inspection • Using a cylinder gauge, measure the bore of the plain bearing areas of the cylinder block and the crankcase cover. Plain Bearing Area Bore Service Limit (maximum) (Unit: mm) FE120 FE170 FE250 FE290 FE350, 400 Type D...
  • Page 82: Lubrication System

    3-46 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE Lubrication System Lubrication Method For FE120, 170, 250 As shown in the diagram on the right, the revolution of the crankshaft causes the splash arm that is provided at the big end of the connecting rod to pick up the engine oil from the crankshaft chamber and splash it in a spray form to lubricate the internal parts.
  • Page 83: Oil Pump Disassembly And Reassembly

    DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-47 Lubrication System Oil Pump Disassembly and Reassembly Disassembly • Remove the six retaining bolts from the oil pump cover and remove the oil pump cover, gasket, and plate, in that order. A: Retaining Bolts B: Oil Pump Cover •...
  • Page 84: Oil Pump Inspection

    3-48 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE Lubrication System • The reassembly is the reverse order of disassembly. • Install the outer rotor and the inner rotor, in that order, making sure to prevent dust from entering the oil pump. CAUTION To install the inner rotor, make sure that the protrusion [B] of the inner rotor properly mates with the cutout [A] at the end of the camshaft.
  • Page 85: Oil Level Warning Device

    DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-49 Lubrication System • Using a micrometer, measure the following parts: Inner Rotor Shaft Diameter (maximum) - for FE290, 350, 400 Service Limit: 12.627 mm (0.4971 in) Outer Rotor Diameter (maximum) - for FE290, 350, 400 Service Limit: 40.467 mm (1.5932 in) Outer Rotor Width (maximum) - for FE290, 350, 400...
  • Page 86 3-50 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE Lubrication System Oil Level Sensor Switch If the oil level becomes lower than the preset value, the sensor switch [A] closes. As a result, the base current [IB1] passes through the Zener diode [Z1] and the resistor [R12] to flow to [TR1] to maintain the circuit. The base current [IB1] is held by the amplified collector current [IC1], and as a result, the spark current does not generate, causing the engine to stop.
  • Page 87 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-51 Lubrication System • When the engine is tilted to a certain angle, the tester should read 0 � � , but remains at ∞, the oil level sensor If the tester does not read 0 switch is faulty.
  • Page 88: Breather

    3-52 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE Lubrication System Breather The function of the breather is to maintain a vacuum in the crankcase to prevent the engine oil from being discharged outside the engine. The breather valve regulates the flow of the air that is created by the movement of the piston by allowing the air to flow from the inside of the crankcase to the outside, while preventing the air from the outside of the crankcase to enter inside.
  • Page 89 � Be careful with hot oil to prevent burns. � Always use a genuine Kawasaki oil filter for replacement. Other brands of oil filters may also fit but they may be of poor quality. • Drain the engine oil into an appropriate container.
  • Page 90: Crankshaft

    3-54 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE Crankshaft Disassembly • Remove the crankcase cover. • If axial play adjustment shims are provided for the crankshaft and the camshaft, remove the shims and identify them so that they can be installed correctly during reassembly. •...
  • Page 91: Crankshaft Inspection

    If a part that affects the axial play has been replaced, the axial play must be adjusted as described below. Shim adjustment is not available on the FE120 and 170. Note: Except the FE170 for pump application. • Place a gasket on the crankcase and measure and record the distance from the gasket surface to the crankshaft gear surface (measurement A).
  • Page 92: Reassembly

    [B] is 17.66 mm, the correct shim thickness is t = 1.53 Crankshaft Axial Play Standard and Service Limit (maximum) (unit: mm) Standard Service Limit FE120 0 ~ 0.24 (0 ~ 0.009 in) 0.5 (0.0197 in) FE170 0.03 ~ 0.30 (0.0011 ~ 0.0118 in) 0.5 (0.0197 in)
  • Page 93: Balancer

    DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-57 Balancer Engine vibration is generated primarily by the inertia that is created through the reciprocal movement mass such as the piston, piston pin, piston ring, and the small end of the connecting rod. On the FE400, 350, 290, and 250, a reciprocal movement balancer system in which balance weight is linked to the crankshaft has been adopted.
  • Page 94: Reciprocal Movement Balancer

    3-58 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE Balancer Reciprocal Movement Balancer (FE400, 350, 290, 250) Disassembly • Remove the retaining nuts from the balancer guide and pull out the balancer guide from the crankcase. • Remove the connecting rod bolt and remove the connecting rod cap. •...
  • Page 95: Uniaxial Rotation Balancer (fe170)

    DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-59 Balancer • Using a micrometer, measure the balancer guide hole bore of the balance weight in several places. Balancer Guide Hole Bore Service Limit (maximum) FE250, 290: 26.118 mm (1.0283 in) FE350, 400: 26.097 mm (1.0274 in) If the measured value is greater than the service limit, replace the balance weight.
  • Page 96 3-60 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE Balancer Balancer Shaft Journal Diameter Service Limit (minimum) PTO Side Flywheel Side FE170: 14.943 mm (0.5883 in) 14.933 mm (0.5879 in) If the measured value is smaller than the service limit, replace the balancer shaft. * For details on the bore of the balancer shaft bearing hole, refer to the section on Crankcase/Plain Bearing.
  • Page 97: Camshaft

    DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-61 Camshaft Disassembly • Remove the crankcase cover. • If axial play adjustment shims are provided for the crankshaft and the camshaft, remove the shims and identify them so that they can be installed correctly during reassembly. •...
  • Page 98: Reassembly

    Using a micrometer, measure the camshaft journal in several places. Camshaft Journal Diameter Service Limit (minimum) (Unit: mm) PTO Side Flywheel Side Type D Type G Type D, G 14.910 19.930 14.910 FE120 (0.5870 in) (0.7846 in) (0.5870 in) 15.910 24.930 15.910 FE170 (0.6264 in) (0.9815 in) (0.6264 in) 19.927...
  • Page 99: Camshaft Axial Play Adjustment

    If a part that affects the axial play has been replaced, the axial play must be adjusted as described below. Shim adjustment is not available on the FE120 and 170. • Place a gasket on the crankcase and measure and record the distance from the gasket surface to the crankshaft gear surface (measurement A).
  • Page 100 3-64 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE Camshaft...
  • Page 101 Service Limit (maximum) - for Type G (Unit: mm) Srandard Service Limit FE120, 170 0.08 ~ 0.34 (0.0031 ~ 0.0134 in) 0.50 (0.0197 in) FE250 0.05 ~ 0.17 (0.0020 ~ 0.0067 in) 0.35 (0.0138 in) FE290, 350, 400 0.07 ~ 0.21 (0.0028 ~ 0.0083 in)

This manual is also suitable for:

Fe170Fe250Fe400Fe290Fe350

Comments to this Manuals

Symbols: 0
Latest comments:
  • Mike Feb 24, 2017 07:56:
    Nice manual very complete wit excellent trouble shooting info
    tx
  • Paul Oct 31, 2015 06:24:
    Require info re no compressio​n