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Kawasaki FS481V Service Manual

4-stroke air-cooled v-twin gasoline engine.
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FS481V, FS541V, FS600V
FX481V, FX541V, FX600V
4-Stroke Air-Cooled V-Twin Gasoline Engine
Service Manual

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Table of Contents

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   Summary of Contents for Kawasaki FS481V

  • Page 1 FS481V, FS541V, FS600V FX481V, FX541V, FX600V 4-Stroke Air-Cooled V-Twin Gasoline Engine Service Manual...
  • Page 3: General Information

    Quick Reference Guide General Information Periodic Maintenance Fuel System Cooling System Engine Top End Lubrication System Camshaft/Crankshaft Starter System Electrical System Troubleshooting 10 j This quick reference guide will assist you in locating a desired topic or pro- cedure. •Bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page.
  • Page 5 All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2009 Kawasaki Heavy Industries, Ltd. First Edition (1):Aug. 6, 2009 (K)
  • Page 6: List Of Abbreviations

    LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: Emission Control Information

    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems (EM) in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board.
  • Page 8: How To Use This Manual

    • Use proper tools and genuine Kawasaki en- gine parts. Genuine parts provided as spare • Indicates a procedural step or work to be parts are listed in the Parts Catalog.
  • Page 9 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................
  • Page 10: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to service the engine, carefully read the applicable section to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been in- cluded wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is required for successful work.
  • Page 11 GENERAL INFORMATION 1-3 Before Servicing (12)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. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole.
  • Page 12 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.
  • Page 13 GENERAL INFORMATION 1-5 Model Identification FX Models (Electric Starter Model) FX Models (Recoil Starter Model)
  • Page 14 1-6 GENERAL INFORMATION Model Identification FS Models (Electric Starter Model) FS Models (Recoil Starter Model) Cylinder Number Designation: No.1 Cylinder is the left-hand cylinder viewed from the intake pipe. No.2 Cylinder is the right-hand cylinder viewed from the intake pipe.
  • Page 15 GENERAL INFORMATION 1-7 General Specifications Item FS481V, FS541V, FS600V, FX481V, FX541V, FX600V Type of Engine Forced air-cooled, vertical shaft, OHV, 4-stroke gasoline engine Cylinder Layout 90 V-Twin Bore × Stroke 73 mm × 72 mm (2.87 in. × 2.84 in.) Piston Displacement 603 cm³...
  • Page 17: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... Special Tools .......................... Periodic Maintenance Procedures..................Fuel System......................... Low Idle Speed Adjustment ....................High Idle Speed Adjustment ..................... Fuel System Cleanliness Inspection ................. Element Cleaning and Inspection ..................
  • Page 18: Periodic Maintenance Chart

    ♦Clean and lap valve seating surface • ♦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.
  • Page 19: Torque And Locking Agent

    PERIODIC MAINTENANCE 2-3 Torque and Locking Agent The following tables list the tightening torque for the major fasteners and the parts requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: EO: Apply oil to the threads. L: Apply a non-permanent locking agent to the threads.
  • Page 20: Periodic Maintenance

    2-4 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Rocker Cover Bolts 0.60 52 in·lb Spark Plugs Valve Clearance Adjusting Locknuts 97 in·lb Lubrication System Engine Oil Drain Plug 0.70 61 in·lb Oil Filler Mounting Bolt 0.90 78 in·lb Oil Filter...
  • Page 21: Specifications

    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 3 600 r/min (rpm) Air Cleaner: Type Dual stage filtration system Pre-cleaner:...
  • Page 22: Special Tools

    2-6 PERIODIC MAINTENANCE Special Tools Valve Seat Cutter, 45° - 27.5: Valve Seat Cutter Holder Bar: 57001-1114 57001-1128 Valve Seat Cutter, 45° - 32: Valve Seat Cutter, 32° - 33: 57001-1115 57001-1199 Valve Seat Cutter, 32° - 28: Valve Seat Cutter Holder, 6: 57001-1119 57001-1360...
  • Page 23: Periodic Maintenance Procedures

    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. Low Idle Speed Adjustment • Disconnect all possible external loads from the engine. •...
  • Page 24: Fuel System Cleanliness Inspection

    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. • Move the throttle lever on dash to obtain the specified high idle speed and leave it there.
  • Page 25: Element Cleaning And Inspection

    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. NOTE ○...
  • Page 26: Valve Clearance Inspection

    2-10 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 covers (see Cylinder Head Assembly Removal in the Engine Top End chapter). •...
  • Page 27: Valve Seat Inspection

    PERIODIC MAINTENANCE 2-11 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) • Do not overtighten the valve clearance adjusting locknuts. •...
  • Page 28 2-12 PERIODIC MAINTENANCE 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. 2. Do not drop or hit the valve seat cutter, or the diamond particles may fall off.
  • Page 29 PERIODIC MAINTENANCE 2-13 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 30: Lubrication System

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures • When lapping is completed, wash all parts in solvent to remove lapping compound. Dry the parts thoroughly. • Note the position of the lapping mark on the valve face. The lapping mark should appear on or near the center of the valve face.
  • Page 31: Oil Filter Replacement

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • Remove the oil filler cap and pour in the specified type and the amount of oil. Engine Oil: Grade: SJ or higher class Viscosity: SAE40, SAE30, SAE10W-30/SAE10W-40, or SAE5W-20 Capacity: [When the oil filter is not removed] 1.5 L (1.6 US qt) [When the oil filter is removed] 1.7 L (1.8 US qt)
  • Page 32: Electrical System

    2-16 PERIODIC MAINTENANCE 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 33 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 ....................3-11 Governor Arm Installation ....................3-11 Governor Assembly Removal ................... 3-12 Governor Assembly Installation ..................
  • Page 34: Exploded View

    3-2 FUEL SYSTEM Exploded View FX Models...
  • Page 35 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 Intake Pipe Mounting Nut 0.60 52 in·lb Control Panel and Intake Pipe Mounting 0.60 52 in·lb Float Chamber Mounting Screw (Recoil...
  • Page 36 3-4 FUEL SYSTEM Exploded View FS Models...
  • Page 37 FUEL SYSTEM 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Carburetor and Intake Pipe Mounting Nut 0.60 52 in·lb Control Panel and Intake Pipe Mounting Nut 0.60 52 in·lb Float Chamber Mounting Screw (Recoil 0.46 40 in·lb Starter Model) Intake Manifold Bolts 0.60 52 in·lb...
  • Page 38 3-6 FUEL SYSTEM Exploded View...
  • Page 39 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 Shaft Plate Screws 0.20 18 in·lb EO: Apply engine oil. R: Replacement Parts...
  • Page 40: Specifications

    3-8 FUEL SYSTEM Specifications Item Standard Carburetor Specifications: Make/ Type: Electric Starter Model: FS481V Walbro/LMF-28 FS541V Walbro/LMF-27 FS600V Walbro/LMF-24 FX481V Walbro/LMF-30 FX541V Walbro/LMF-29 FX600V Walbro/LMF-25 Recoil Starter Model: FS481V Walbro/LMF-35 FS541V Walbro/LMF-33 FS600V Walbro/LMF-31 FX481V Walbro/LMF-36 FX541V Walbro/LMF-34 FX600V Walbro/LMF-32 Throttle Bore Diameter 24 mm (0.94 in.)
  • Page 41 FUEL SYSTEM 3-9 Specifications Item Standard Fuel Pump Type Pulse-diaphragm pump Governor Type Flyweight all speed governor (1) Idle speeds may vary depending on each equipment. Refer to the equipment specification. (2) Other fuel requirements: See Fuel and oil recommendations in Owner’s Manual.
  • Page 42: Governor Link Mechanism

    3-10 FUEL SYSTEM Governor Link Mechanism Control Panel Assembly Removal • Remove: Control Panel and Intake Pipe Mounting Nut [A] Control Panel Mounting Bolt [B] • Remove the control panel assembly [A] while unhooking the governor spring [B] end loop at the panel bracket. NOTE ○...
  • Page 43: Governor Arm Removal

    FUEL SYSTEM 3-11 Governor Link Mechanism Governor Arm Removal • Remove the intake pipe (see Intake Pipe Removal). • Unhook the throttle link spring [A] and throttle link rod [B] from the throttle shaft lever [C] while pull off the carbure- tor.
  • Page 44: Governor Assembly Removal

    3-12 FUEL SYSTEM Governor Link Mechanism Governor Assembly Removal • Remove: Camshaft (see Camshaft, Tappet Removal in the Camshaft/Crankshaft chapter) Pin [A] Washer ( 30) [B] Snap Rings [C] Washer ( 42) [D] Sleeve [E] Governor Plate [F] Steel Balls [G] Ball Guide [H] Ball Plate [I] Governor Assembly Installation...
  • Page 45: Governor Shaft Installation

    FUEL SYSTEM 3-13 Governor Link Mechanism Governor Shaft Installation • Apply engine oil to the governor shaft. • Insert the governor shaft [A] into the crankcase cover. • Install the governor shaft plate [B] to the shaft. • Tighten: Torque - Governor Shaft Plate Screws [C]: 2.0 N·m (0.20 kgf·m, 18 in·lb) •...
  • Page 46: Carburetor

    3-14 FUEL SYSTEM Carburetor Fuel and Air Flow FS and FX Models (Electric Starter Model) 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 47 FUEL SYSTEM 3-15 Carburetor FS and FX Models (Recoil Starter Model) 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 48: Fuel Shut Off Solenoid Valve

    3-16 FUEL SYSTEM Carburetor Fuel Shut Off Solenoid Valve FS and FX Models (Electric Starter Model) 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 jet [B] simultaneously when the switch key turned to the “OFF”...
  • Page 49: Fuel System Cleanliness Inspection

    FUEL SYSTEM 3-17 Carburetor • Using a properly sized blade screw driver, carefully re- place the main jet [A] with a new one for altitude expected. • Tighten: Torque - Main Jet: 2.3 N·m (0.23 kgf·m, 20 in·lb) • Replace the float chamber gasket with a new one. •...
  • Page 50: Intake Pipe Removal

    3-18 FUEL SYSTEM Carburetor Intake Pipe Removal FS and FX Models (Electric Starter Model) • Remove: Element Assembly (see Element Removal) Control Panel Assembly (see Control Panel Assembly Removal) Intake Pipe Mounting Nut [A] Ground Lead [B] Clamp [C] Breather Hose [D] Intake Pipe [E] FS and FX Models (Recoil Starter Model) •...
  • Page 51: Carburetor Removal

    FUEL SYSTEM 3-19 Carburetor • Connect the breather hose [A] so that the clamp knob [B] faces the downward. • Install the removed parts (see appropriate chapters). Carburetor Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the engine switch OFF.
  • Page 52: Carburetor Installation

    3-20 FUEL SYSTEM Carburetor Carburetor Installation • Clean the mating surface of the carburetor and intake manifold. • Replace the gaskets [A] with new ones. • Install the insulator [B], carburetor [C] and gaskets se- quence as shown in the figure. •...
  • Page 53: Carburetor Disassembly/assembly

    FUEL SYSTEM 3-21 Carburetor • Install the fuel tube [A] fully so that the clamp knob [B] faces the downward. • Install the removed parts (see appropriate chapters). • After installation, adjust the idle speed (see Low/High Idle Speed Adjustment in the Periodic Maintenance chapter). Carburetor Disassembly/Assembly •...
  • Page 54: Carburetor Cleaning

    3-22 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. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents to clean the carburetors.
  • Page 55: Carburetor Inspection

    FUEL SYSTEM 3-23 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; this includes any appliance with a pilot light.
  • Page 56: Fuel Shut Off Solenoid Valve Test

    3-24 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. Good [A] Not Good [B] If either the needle or the seat is worn or damaged, re-...
  • Page 57: Intake Manifold

    FUEL SYSTEM 3-25 Intake Manifold Intake Manifold Removal • Remove the carbretor (see Carbretor Removal). • Unscrew the intake manifold mounting bolts [A]. • Remove the intake manifold [B] and gaskets. Intake Manifold Installation • Replace the intake manifold gaskets [A] with new ones. •...
  • Page 58: Fuel Pump, Fuel Filter

    3-26 FUEL SYSTEM 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. Fuel Pump Removal •...
  • Page 59: Fuel Filter Removal/installation

    FUEL SYSTEM 3-27 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 60: Air Cleaner

    3-28 FUEL SYSTEM 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]. FS Models • Turn the fasteners [A] clockwise. •...
  • Page 61: Element Installation

    FUEL SYSTEM 3-29 Air Cleaner Element Installation FX Models • Slide the primary element into place in the air cleaner body. • Install the cap direction as shown in the figure. Upside [A] 45° [B] • Fasten the two retaining clamps [C]. FS Models •...
  • Page 62: Element Cleaning And Inspection

    3-30 FUEL SYSTEM Air Cleaner • Install the intake hose [A], and tighten the clamp [B]. • Install the air cleaner cover [A]. • Turn the fasteners [B] counterclockwise. Element Cleaning and Inspection Air cleaner elements are not recommended to be cleaned, and each air cleaner element should be replaced with new ones.
  • Page 63: Air Cleaner Body And Bracket Installation

    FUEL SYSTEM 3-31 Air Cleaner 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) • Set the air cleaner body [A] onto the lower bracket so that the air intake duct [B] is facing upward.
  • Page 65 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 66: Exploded View

    4-2 COOLING SYSTEM Exploded View FS and FX Models (Electric Starter Model)
  • Page 67: Cooling System

    COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cooling Fan Mounting Bolts 0.60 52 in·lb Cooling Fan Screen Screws 0.31 27 in·lb Engine Shroud Bolts (FX Models) 0.60 52 in·lb Engine Shroud Bolts (FS Models) 0.90 78 in·lb Fan Housing Bolts (FX Models) 0.60 52 in·lb...
  • Page 68 4-4 COOLING SYSTEM Exploded View FS and FX Models (Recoil Starter Model)
  • Page 69 COOLING SYSTEM 4-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cooling Fan Plate Mounting Bolts 0.60 52 in·lb Engine Shroud Bolts (FX Models) 0.60 52 in·lb Engine Shroud Bolts (FS Models) 0.90 78 in·lb Fan Housing Bolts (FX Models) 0.60 52 in·lb Fan Housing Bolts (FS Models)
  • Page 70: Cooling Fan

    4-6 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. Cooling Fan Inspection •...
  • Page 71: Engine Shroud

    COOLING SYSTEM 4-7 Engine Shroud Engine Shroud Removal FS and FX Models (Electric Starter Model) • Remove: Fan Housing (see Flywheel and Stator Coil Removal in the Electrical System chapter) Lift Hook (see Cylinder Head Assembly Removal in the Engine Top End chapter) Stator Coil Lead Connector (see Regulator Removal in the Electrical System chapter) Spark Plug Caps [A]...
  • Page 72 4-8 COOLING SYSTEM Engine Shroud FS and FX Models (Recoil Starter Model) • Remove: Fan Housing (see Flywheel and Stator Coil Removal in the Electrical System chapter) Lift Hook (see Cylinder Head Assembly Removal in the Engine Top End chapter) Spark Plug Caps [A] Engine Shroud Bolts [B] Engine Shrouds [C]...
  • Page 73: Engine Shroud Installation

    COOLING SYSTEM 4-9 Engine Shroud Engine Shroud Installation FS and FX Models (Electric Starter Model) • Install the engine shrouds [A]. • Tighten the engine shroud bolts [B]. Torque - Engine Shroud Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) (FX Models) Engine Shroud Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) (FS Models) •...
  • Page 74 4-10 COOLING SYSTEM Engine Shroud FS and FX Models (Recoil Starter Model) • Install the engine shrouds [A]. • Tighten the engine shroud bolts [B]. Torque - Engine Shroud Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) (FX Models) Engine Shroud Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) (FS Models) •...
  • Page 75 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 ......................5-10 Push Rod Installation ......................5-10 Push Rod Inspection......................
  • Page 76: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 77: Engine Top End

    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) 27.4 Cylinder Head Bolts (L = 70 mm) 27.4 Lift Hook Bolt 0.60 52 in·lb Rocker Arm Bracket Bolts 14.7...
  • Page 78: Specifications

    5-4 ENGINE TOP END Specifications Item Service Limit Cylinder Head: 448 kPa (64 psi) @ Engine Oil Temperature 50 ∼ Cylinder Compression (MIN) 60°C (122 ∼ 144°F), Cranking Speed 500 rpm/5 Seconds Cylinder Head Warp 0.05 mm (0.002 in.) Valves: Valve Head Thickness: Intake, Exhaust 0.35 mm (0.0138 in.)
  • Page 79 ENGINE TOP END 5-5 Specifications Item Standard Valve Clearance: 0.10 ∼ 0.15 mm (0.0039 ∼ 0.059 in.) Intake, Exhaust Valve Seating Surface Angle: Intake, Exhaust 45° Valve Seating Surface Width: 0.8 ∼ 1.4 mm (0.031 ∼ 0.055 in.) Intake 0.8 ∼ 1.4 mm (0.031 ∼ 0.055 in.) Exhaust Valves Guide Inside Diameter: 6.000 ∼...
  • Page 80: Special Tools

    5-6 ENGINE TOP END Special Tools Piston Ring Compressor Belt, 67 ∼ 79: Piston Ring Pliers: 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...
  • Page 81: Cylinder Head

    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 82: Cylinder Head Assembly Removal

    5-8 ENGINE TOP END Cylinder Head Cylinder Head Assembly Removal • Remove: Fan Housing (see Flywheel and Stator Coil Removal in the Electrical System chapter) Bolt [A] Lift Hook [B] • Remove: Intake Manifold (see Intake Manifold Removal in the Fuel System chapter) Engine Shroud (see Engine Shroud Removal in the Cooling System chapter)
  • Page 83: Cylinder Head Assembly Installation

    ENGINE TOP END 5-9 Cylinder Head Cylinder Head Assembly Installation • Clean the mating surfaces of the cylinder heads and cylin- ders. • Replace the gaskets with new ones. • Install the dowel pins [A] • Set each piston at the T.D.C [A] of the compression stroke.
  • Page 84: Push Rod Removal

    5-10 ENGINE TOP END Cylinder Head • Install: Spark Plugs (see Spark Plug Installation in the Electrical System chapter) Engine Shroud (see Engine Shroud Installation in the Cooling System chapter) Lift Hook [A] • Tighten: Torque - Lift Hook Bolt [B]: 5.9 N·m (0.60 kgf·m, 52 in·lb) •...
  • Page 85 ENGINE TOP END 5-11 Cylinder Head • Remove: Valve Clearance Adjusting Locknuts [A] Valve Clearance Adjusting Bolts [B] and Washer Collar Rocker Arm [C] • Remove: Push Rod (see Push Rod Removal) Rocker Arm Bracket Bolts [A] Rocker Arm Brackets [B] •...
  • Page 86: Cylinder Head Cleaning

    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. Torque - Rocker Arm Bracket Bolts: 14.7 N·m (1.5 kgf·m, 11 ft·lb) •...
  • Page 87: Cylinder Head Inspection

    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. If warp exceeds the service limit, repair the head by lap- ping the mating surface with emery paper secured to a surface plate (first No.
  • Page 88: Valves

    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. Valve Seat Inspection • Refer to the Valve Seat Inspection in the Periodic Mainte- nance chapter.
  • Page 89: Valve Guide Inside Diameter

    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. If the measurement is more than the service limit, replace the cylinder head with a new one.
  • Page 90: Cylinder, Piston

    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) • Turn the crankshaft to expose the connecting rod cap bolts [A].
  • Page 91: Piston Installation

    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 92 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” Mark on the connecting rod to face the flywheel side.
  • Page 93: Piston/cylinder Seizure

    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. • Apply molybdenum disulfide oil solution oil to the inner surface [A] of the connecting rod big end [B] and caps [C].
  • Page 94: Piston Ring And Ring Groove Wear

    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. Piston Ring and Ring Groove Wear •...
  • Page 95: Piston Ring End Gap

    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 96: Piston Diameter

    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. If the measurement is less than the service limit, replace the piston with a new one.
  • Page 97 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. • Clean the cylinder at the top and bottom of the cylinder to remove burns and pieces of the base and head gasket.
  • Page 99 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......................Oil Filter Removal ......................Oil Filter Installation ......................Pressurized Lubrication System .....................
  • Page 100: Exploded View

    6-2 LUBRICATION SYSTEM Exploded View...
  • Page 101 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 0.90 78 in·lb Oil Filter 11.8 104 in·lb Oil Pump Cover Plate Bolts 0.60 52 in·lb EO: Apply engine oil. G: Apply grease.
  • Page 102: Engine Oil Flow Chart

    6-4 LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 103: Specifications

    LUBRICATION SYSTEM 6-5 Specifications Item Standard Engine Oil: Grade SJ or higher class Viscosity SAE40, SAE30, SAE10W-30/SAE10W-40, or SAE5W-20 Capacity: When the oil filter is not 1.5 L (1.6 US qt) removed When the oil filter is removed 1.7 L (1.8 US qt) Level Operating range (grid area (ADD and FULL)) on dipstick Oil Pressure...
  • Page 104: Special Tools

    6-6 LUBRICATION SYSTEM Special Tools Oil Pressure Gauge, 10 kgf/cm²: Oil Pressure Gauge Adapter, PT 1/8: 57001-164 57001-1033...
  • Page 105: Engine Oil And Oil Filter

    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 • Refer to the Engine Oil Level Inspection in the Periodic Maintenance chapter.
  • Page 106: Pressurized Lubrication System

    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, and return to the crankcase.
  • Page 107: Oil Pump, Relief Valve

    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 System chapter) Bolts [A] Pump Cover Plate [B] •...
  • Page 108 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. Outer Rotor Outside Diameter Service Limit: 52.31 mm (2.059 in.)
  • Page 109: Oil Screen

    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 111 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..................... Crankcase Disassembly ....................Crankcase Assembly ......................Crankcase Inspection ....................... Crankcase and Crankcase Cover Cleaning..............
  • Page 112: Exploded View

    7-2 CAMSHAFT/CRANKSHAFT Exploded View...
  • Page 113 CAMSHAFT/CRANKSHAFT 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Breather Chamber Cover Bolts 0.60 52 in·lb Breather Valve Mounting Screw 0.20 18 in·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...
  • Page 114: Specifications

    7-4 CAMSHAFT/CRANKSHAFT Specifications Item Service Limit Camshaft, Tappet: Cam Lobe Height: Intake 29.62 mm (1.166 in.) Exhaust 29.62 mm (1.166 in.) Camshaft Journal Diameter: PTO Side 15.99 mm (0.630 in.) Flywheel Side 15.99 mm (0.630 in.) Camshaft Bearing Inside Diameter: Crankcase 16.14 mm (0.635 in.) Crankcase Cover...
  • Page 115: Special Tool

    CAMSHAFT/CRANKSHAFT 7-5 Special Tool Bearing Driver Set: Gasket-Liquid, TB1217H: 57001-1129 92104-7001...
  • Page 116: Crankcase

    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). • Remove: Oil Filter (see Oil Filter Replacement in the Periodic Maintenance chapter) Intake Manifold (see Intake Manifold Removal in the Fuel System chapter)
  • Page 117: Crankcase Cover Assembly

    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. • With a high-flash point solvent, clean off the mating sur- faces of the crankcase and the cover, and wipe them dry.
  • Page 118: Crankcase Cover Inspection

    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 119: Crankcase Inspection

    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. ○ Thoroughly pack high-temperature grease to 60% volume into the space [B] between the seal lip [C] and dust lip [D].
  • Page 120: Breather

    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. The blow-by gases are led to the breather chamber through the crankcase and camshaft.
  • Page 121 CAMSHAFT/CRANKSHAFT 7-11 Breather FX Models (Recoil Starter Model)
  • Page 122 7-12 CAMSHAFT/CRANKSHAFT Breather FS Models (Electric Starter Model)
  • Page 123 CAMSHAFT/CRANKSHAFT 7-13 Breather FS Models (Recoil Starter Model)
  • Page 124: Breather Valve Removal

    7-14 CAMSHAFT/CRANKSHAFT Breather Breather Valve Removal • Remove the stator coil (see Flywheel and Stator Coil Re- moval in the Electrical System chapter). • Cut off the band [A]. • Remove: Bolts [B] Breather Chamber Cover [C] • Remove: Breather Pipe [A] (see Breather Pipe Removal) Screw [B] Back Plate [C] Reed Valve [D]...
  • Page 125: Breather Valve Inspection

    CAMSHAFT/CRANKSHAFT 7-15 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 126: Camshaft, Tappet

    7-16 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). • Remove: Crankcase Cover (see Crankcase Cover Removal) Cylinder Head Assembly (see Cylinder Head Assembly Removal in the Engine Top End chapter) •...
  • Page 127: Camshaft Assembly

    CAMSHAFT/CRANKSHAFT 7-17 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. ○ While shaking the camshaft, check if the ACR weight [B] swings smoothly.
  • Page 128 7-18 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. Camshaft Bearing Inside Diameter (Crankcase Cover) Service Limit: 16.14 mm (0.635 in.)
  • Page 129: Crankshaft, Connecting Rod

    CAMSHAFT/CRANKSHAFT 7-19 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). Crankshaft Removal • Remove: Camshaft (see Camshaft, Tappet Removal) Connecting Rod and Pistons (see Piston Removal in the...
  • Page 130: Connecting Rod Bend/twist

    7-20 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 131: Connecting Rod Big End Bearing/crankpin Wear

    CAMSHAFT/CRANKSHAFT 7-21 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. Crankpin Width Service Limit: 40.0 mm (1.57 in.) Connecting Rod Big End Bearing/Crankpin Wear •...
  • Page 132: Crankshaft Main Journal/wear

    7-22 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. Crankshaft Journal Diameter Service Limit: PTO Side [A] 37.90 mm (1.492 in.)
  • Page 133 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 ......................Starter Motor Disassembly....................Starter Motor Assembly ....................8-11 Starter Motor Brush Inspection ..................
  • Page 134: Exploded View

    8-2 STARTER SYSTEM Exploded View FS and FX Models (Electric Starter Model)
  • Page 135: Starter System

    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 (FS Models) 3.95 0.40 35 in·lb 3. FS Models G: Apply grease. R: Replacement Parts...
  • Page 136 8-4 STARTER SYSTEM Exploded View FS and FX Models (Recoil Starter Model)
  • Page 137 STARTER SYSTEM 8-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Recoil Starter Mounting Bolts 0.60 52 in·lb Recoil Starter Retainer Screw 0.60 52 in·lb Starter Motor Plate Mounting Bolts 19.6 4. FS Models G: Apply grease. R: Replacement Parts...
  • Page 138: Specifications

    8-6 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.) FS Models – – – 10.16 mm (0.4 in.) Commutator Groove Depth: FX Models 0.6 mm (0.02 in.) 0.2 mm (0.008 in.) FS Models...
  • Page 139: Starter Motor Removal

    STARTER SYSTEM 8-7 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. Starter Motor Installation • Clean the starter motor and engine mounting flanges to ensure good electrical contact and tighten the mounting bolts.
  • Page 140: Starter Motor Test

    8-8 STARTER SYSTEM Electric Starter System • Disconnect the switch lead [A]. • Set the hand tester to the R × 1 Ω position and connect the leads as shown in the figure. Switch Terminal [A] To Ground [B] If the tester does not read close to 0 Ω, the solenoid is faulty.
  • Page 141: Starter Motor Disassembly

    STARTER SYSTEM 8-9 Electric Starter System Starter Motor Disassembly FX Models • Loosen the terminal nut [A]. • Remove the lead [B] from the starter motor to the sole- noid. • Unscrew the mounting nuts [A] and remove the solenoid assembly [B].
  • Page 142 8-10 STARTER SYSTEM Electric Starter System • Remove: Brush Holder [A] Yoke [B] • Remove the armature assembly [A] with the pinion gear fork [B]. • Remove the front stopper [A]. • Push the rear stopper [B] downward and remove the snap ring [C].
  • Page 143: Starter Motor Assembly

    STARTER SYSTEM 8-11 Electric Starter System Starter Motor Assembly FX Models • Apply a small amount of grease to the armature shaft [A] as shown in the figure. • Do not reuse the snap ring [B]. Replace it with a new one. •...
  • Page 144 8-12 STARTER SYSTEM Electric Starter System • Install the yoke so that the slit [A] fit the projection [B] of the pinion gear fork. • Install the brush holder [A]. • Install the brushes [B] to the brush holder. • Install the springs [A].
  • Page 145 STARTER SYSTEM 8-13 Electric Starter System • Engage the hook on the starter solenoid with the hook [A] on the pinion gear fork [B]. • Tighten the solenoid mounting nut. FS Models • Using the suitable tool, hold the brushes. •...
  • Page 146: Starter Motor Brush Inspection

    8-14 STARTER SYSTEM Electric Starter System Starter Motor Brush Inspection • Measure the overall length [A] of each brush. If the brushes are shorter than the service limit, replace them. FX Models [B] FS Models [C] Brush Length Standard: FX Models 10.0 mm (0.39 in.) FS Models –...
  • Page 147 STARTER SYSTEM 8-15 Electric Starter System • Measure the depth of the grooves between the commu- tator segments. If the grooves are shallower than the specified limit, re- place the armature with a new one. If the grooves are only dirty, clean them carefully. Commutator Groove Depth Standard: FX Models...
  • Page 148: Yoke Assembly Inspection

    8-16 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. If the resistance it too high or even infinite, the armature winding has an open circuit.
  • Page 149: Pinion Clutch Inspection

    STARTER SYSTEM 8-17 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. If the meter dose not read close ∼ 0 Ω, the yoke assembly is faulty.
  • Page 150: Recoil Starter Installation

    8-18 STARTER SYSTEM Electric Starter System Recoil Starter Installation • Install the recoil starter [A] and tighten the mounting bolts [B]. Torque - Recoil Starter Mounting Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) FX Models [C] FS Models [D] Recoil Starter Disassembly •...
  • Page 151: Recoil Starter Assembly

    STARTER SYSTEM 8-19 Electric Starter System • Slowly lift the reel [A] straight up out of the case [B]. • Hold the reel [A] with spring side downward in a suitable container and tap reel to remove recoil spring [B]. Recoil Starter Assembly WARNING Wear gloves during the recoil spring installation to...
  • Page 152 8-20 STARTER SYSTEM Electric Starter System • Install the pawls [A]. • Apply a non-permanent locking agent to the recoil starter retainer screw [A]. • Install the retainer assembly [B]. • Tighten: Torque - Recoil Starter Retainer Screw: 5.9 N·m (0.60 kgf·m, 52 in·lb) •...
  • Page 153 ELECTRICAL SYSTEM 9-1 Electrical System Table of Contents Exploded View........................Specifications ......................... Special Tool ..........................Wiring Diagram........................Precautions..........................9-11 Charging System ........................9-12 Flywheel and Stator Coil Removal..................9-12 Flywheel and Stator Coil Installation................. 9-16 Charging System Operational Inspection ................. 9-20 Stator Coil Resistance ......................
  • Page 154: Exploded View

    9-2 ELECTRICAL SYSTEM Exploded View FS and FX Models (Electric Starter Model)
  • Page 155 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 5. FS Models G: Apply dielectric grease.
  • Page 156 9-4 ELECTRICAL SYSTEM Exploded View FS and FX Models (Recoil Starter Model)
  • Page 157 ELECTRICAL SYSTEM 9-5 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 5. FS Models...
  • Page 158: Specifications

    9-6 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Charging System Regulated Output Voltage 14.1 V DC 15 V DC (Electric Starter Model only) Stator Coil Resistance: 0.1 ∼ 0.14 Ω Electric Starter Model – – – 4.4 ∼ 15 Ω –...
  • Page 159: Special Tool

    ELECTRICAL SYSTEM 9-7 Special Tool Hand Tester: 57001-1394...
  • Page 160: Wiring Diagram

    9-8 ELECTRICAL SYSTEM Wiring Diagram FX Models (Electric Starter Model)
  • Page 161 ELECTRICAL SYSTEM 9-9 Wiring Diagram FS Models (Electric Starter Model)
  • Page 162 9-10 ELECTRICAL SYSTEM Wiring Diagram FS and FX Models (Recoil Starter Model)
  • Page 163: Precautions

    ELECTRICAL SYSTEM 9-11 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 164: Charging System

    9-12 ELECTRICAL SYSTEM Charging System Flywheel and Stator Coil Removal FX Models (Electric Starter Model) • 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 chapter) Stator Coil Lead Connector (see Regulator Removal) Bolts [A] and Guard [B]...
  • Page 165 ELECTRICAL SYSTEM 9-13 Charging System • Hold the flywheel with a suitable tool [A], remove the fly- wheel bolt [B] and washer. • Using a suitable flywheel puller [A], remove the flywheel [B]. CAUTION Always use flywheel puller. FX Models (Electric Starter Model) •...
  • Page 166 9-14 ELECTRICAL SYSTEM Charging System FX Models (Recoil Starter Model) • Remove: Recoil Starter (see Recoil Starter Removal in the Starter System chapter) Air Cleaner (see Air Cleaner and Bracket Removal in the Fuel System chapter) Fuel Pump (see Fuel Pump Removal in the Fuel System chapter) Bolts [A] Fan Housing [B]...
  • Page 167 ELECTRICAL SYSTEM 9-15 Charging System • Remove: Pulley Plate [A] Bolts [B] Cooling Fan Plate [C] Cooling Fan [D] • Using a suitable flywheel puller [A], remove the flywheel [B]. CAUTION Always use flywheel puller. FX Models (Recoil Starter Model) •...
  • Page 168: Flywheel And Stator Coil Installation

    9-16 ELECTRICAL SYSTEM Charging System Flywheel and Stator Coil Installation FS and FX Models (Electric Starter Model) • Install the stator coil and tighten the screws. Torque - Stator Coil Screws: 3.4 N·m (0.35 kgf·m, 30 in·lb) • Using a cleaning fluid, clean off any oil or dirt on the fol- lowing portions and dry them with a clean cloth.
  • Page 169 ELECTRICAL SYSTEM 9-17 Charging System FS Models (Electric Starter Model) • Attach the stator coil lead [A], stop switch lead and sole- noid valve connector lead to the engine shroud with the band [B]. • Install the fan housing. • Tighten: Torque - Fan Housing Bolts (FX Models): 5.9 N·m (0.60 kgf·m, 52 in·lb)
  • Page 170 9-18 ELECTRICAL SYSTEM Charging System FS and FX Models (Recoil Starter Model) • Install the stator coil and tighten the screws. Torque - Stator Coil Screws: 3.4 N·m (0.35 kgf·m, 30 in·lb) • Using a cleaning fluid, clean off any oil or dirt on the fol- lowing portions and dry them with a clean cloth.
  • Page 171 ELECTRICAL SYSTEM 9-19 Charging System • Put the washer [A] as shown so that the “0” mark [B] faces • Tighten: Torque - Flywheel Bolt [C]: 56 N·m (5.7 kgf·m, 41 in·lb) • Install the ignition coils (see Ignition Coil Installation). FX Models (Recoil Starter Model) •...
  • Page 172: Charging System Operational Inspection

    9-20 ELECTRICAL SYSTEM Charging System Charging System Operational Inspection FS and FX Models (Electric Starter Model) • Check the battery condition. NOTE ○ Always check the battery condition before judging other parts of the charging system. The battery must be fully charged for accurate charging system tests.
  • Page 173: Unregulated Stator Output

    ELECTRICAL SYSTEM 9-21 Charging System If the measured value is not within the specification, re- place the stator coil with a new one. If the coil has normal resistance, but the voltage inspec- tion shows the alternator to be defective; the flywheel magnets have probably weakened, and the flywheel must be replaced.
  • Page 174: Regulator Installation

    FS and FX Models (Electric Starter Model) • 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 175: Ignition System

    ELECTRICAL SYSTEM 9-23 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: Inductive Ignition Assemblies Permanent Magnet Flywheel Spark Plugs Stop Switch Co: Core (Lamination) C: Collector...
  • Page 176: Ignition Coil Removal

    9-24 ELECTRICAL SYSTEM Ignition System Ignition Coil Removal • Remove the fan housing (see Flywheel and Stator Coil Removal). • Cut off the band [A]. • Remove: Spark Plug Cap [B] Bolts [C] Stop Switch Lead Connector [D] Ignition Coil #1 [E] Ignition Coil #2 [F] FS and FX Models (Electric Starter Model)/FX Models (Recoil Starter Model) [G]...
  • Page 177: Ignition Coil Installation

    ELECTRICAL SYSTEM 9-25 Ignition System Ignition Coil Installation • Install the ignition coil on the crankcase so that the stop switch lead connector [A] face the upward, and tighten bolt [B] first, then tighten bolt [C]. While tightening bolts, adjust the air gaps to specified gap value as shown. [D]: between left leg of ignition coil and left pole-plate of magnet [E]: between center of ignition coil and right pole-plate of...
  • Page 178: Ignition Coil Inspection

    CAUTION Use only Tester 57001-1394 with new battery at room temperature for this test. A tester other than the Kawasaki Hand Tester should show different readings. If a megger or a meter with a large capacity battery is used, the ignition coil will be damaged.
  • Page 179 TROUBLESHOOTING 10-1 Troubleshooting Table of Contents Engine Troubleshooting Guide ....................10-2 Starter Motor Troubleshooting Guide ..................10-6...
  • Page 180: Troubleshooting

    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. This chart describes typical troubleshooting procedures. Do not unnecessarily disassemble the carburetor, the magneto or the engine unless it has been found to be the cause of malfunctioning.
  • Page 181 TROUBLESHOOTING 10-3 Engine Troubleshooting Guide...
  • Page 182 10-4 TROUBLESHOOTING Engine Troubleshooting Guide...
  • Page 183 TROUBLESHOOTING 10-5 Engine Troubleshooting Guide...
  • Page 184 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 185 Part No.99924-2094-02 Printed in Japan...

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