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Kawasaki FJ400D Service Manual

4-stroke air-cooled gasoline engine.
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FJ400D
4-stroke air-cooled gasoline engine
Service Manual

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Table of Contents

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   Summary of Contents for Kawasaki FJ400D

  • Page 1 FJ400D 4-stroke air-cooled 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 Electrical System Troubleshooting 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 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 Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
  • Page 6 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

    • venient operation. 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)Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips. Before a shaft passes through a seal, apply a little oil, preferably high-temperature grease on the lips to reduce rubber to metal friction.
  • Page 12 1-4 GENERAL INFORMATION Model Identification...
  • Page 13: General Specifications

    GENERAL INFORMATION 1-5 General Specifications Item FJ400D Type of Engine Air-cooled, 4-stroke, OHV, single cylinder gasoline engine Bore × Stroke 82 mm × 76 mm (3.23 in. × 2.99 in.) Piston Displacement 401 mL (24.5 cu in.) Direction of Rotation...
  • Page 15: 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.................. Engine Top End ........................
  • Page 16: Periodic Maintenance Chart

    Clean and lap valve seating surface • 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: 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: L: Apply a non-permanent locking agent to the threads. O: Apply engine oil.
  • Page 18 2-4 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Ignition Coil Bolts 0.60 52 in·lb Spark Plug Starter Motor Mounting Bolts The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts.
  • Page 19: Specifications

    PERIODIC MAINTENANCE 2-5 Specifications Item Standard Fuel System Idle Speed: (1) Low Idle Speed 1 125 ±75 r/min (rpm) High Idle Speed 3 750 ±50 r/min (rpm) Air Cleaner: Type – – – Cleaner – – – Engine Top End Valve Clearance: 0.10 ∼...
  • Page 20: Special Tools

    2-6 PERIODIC MAINTENANCE Special Tools Valve Seat Cutter, 45° - 32: Valve Seat Cutter Holder, 7: 57001-1115 57001-1126 Valve Seat Cutter, 45° - 35: Valve Seat Cutter Holder Bar: 57001-1116 57001-1128 Valve Seat Cutter, 32° - 35: Oil Filter Wrench: 57001-1121 57001-1249 Valve Seat Cutter, 32°...
  • Page 21: Periodic Maintenance Procedures

    PERIODIC MAINTENANCE 2-7 Periodic Maintenance Procedures Fuel System NOTE ○ High and low idle speeds may very depending on the equipment on which the engine is used. Refer to the equipment specification. Low Idle Speed Adjustment • Disconnect all external loads from the engine. •...
  • Page 22: Fuel System Cleanliness Inspection

    2-8 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING Always keep your hands clear of the moving parts. • Move the throttle lever at a dash to the high idle position and adjust the high idle speed set screw [A] to obtain the specified high idle speed.
  • Page 23: Engine Top End

    PERIODIC MAINTENANCE 2-9 Periodic Maintenance Procedures Engine Top End Cylinder Head Cleaning and Inspection • Remove the valves (see Valve Mechanism Removal/In- stallation in the Engine Top End chapter). • Scrape the carbon deposits from the head and exhaust port with a suitable tool [A]. ○...
  • Page 24: Valve Clearance Adjustment

    2-10 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Then check the valve clearance. ○ Using a thickness gauge [A], measure the valve clearance between the rocker arm [B] and the valve stem end. If the valve clearance is incorrect, adjust it. Valve Clearance (when cold) Inlet, Exhaust 0.10 ∼...
  • Page 25 PERIODIC MAINTENANCE 2-11 Periodic Maintenance Procedures NOTE ○ The valve stem and guide must be in good condition or this check will not be valid. Good [A] Too Wide [B] Too Narrow [C] Uneven [D] If the valve seating pattern is not correct, repair the seat. Valve Seating Surface Width (STD) 1.1 ∼...
  • Page 26 2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Marks Stamped on the Cutter The marks stamped on the back of the cutter represent the following. 45° Cutter angle [A] 24.5 Cutter diameter of cutter [B] Operating Procedures • Clean the seat area carefully. •...
  • Page 27 PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures • Use a 32° seat cutter [A] to narrow the seat width to the STD width. ○ Turn the seat cutter one turn at a time while pressing down very lightly. Check the seat width after each turn. CAUTION The 32°...
  • Page 28: Lubrication System

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Lubrication System Oil Level Inspection • Place the engine on a level surface. • Remove the oil filler cap [A] and wipe its dipstick [B] with a clean cloth. • Insert the dipstick into gauge hole [C] without screwing it in, then check the oil Level.
  • Page 29 PERIODIC MAINTENANCE 2-15 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 30: Electrical System

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Spark Plug Cleaning and Gap Inspection • Remove the spark plug (see Spark Plug Removal in the 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.
  • Page 31 FUEL SYSTEM 3-1 Fuel System Table of Contents Exploded View........................Specifications ......................... Governor Link Mechanism...................... Control Panel Assembly Removal ..................Control Panel Assembly Installation ................. Governor Arm Removal ....................Governor Arm Installation ....................Governor Assembly Removal/Inspection................Governor Assembly Installation ..................Governor Shaft Removal ....................
  • Page 32: Exploded View

    3-2 FUEL SYSTEM Exploded View...
  • Page 33 FUEL SYSTEM 3-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Inlet-Pipe Nuts 0.60 52 in·lb Control Panel Bolts 0.70 61 in·lb Governor Arm Clamp Nut 0.60 52 in·lb Choke Valve Screws 0.09 7.8 in·lb Throttle Valve Screws 0.09 7.8 in·lb Pilot Jet (Slow Jet) 0.07 6.1 in·lb...
  • Page 34: Specifications

    3-4 FUEL SYSTEM Specifications Item Standard Caburetors Specifications Make/ Type NIKKI/6C1026-511 Throttle Bore Diameter 26 mm (1.02 in.) Venturi Diameter 20 mm (0.79 in.) Main Jet (MJ) #110 Pilot Jet (PJ) Pilot Screw Turns Out (PS) 2 3/4 ±3/8 (Idle Mixture Screw Turns Out) Float Level Float parallel to carburetor body Idle Speed (1)
  • Page 35: Governor Link Mechanism

    FUEL SYSTEM 3-5 Governor Link Mechanism Control Panel Assembly Removal • Remove the control panel mounting bolts [A]. • Remove the control panel assembly [A] while unhooking the governor spring [B] end loop at the engine speed con- trol lever [C]. Control Panel Assembly Installation •...
  • Page 36: 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 37: Governor Assembly Installation

    FUEL SYSTEM 3-7 Governor Link Mechanism Governor Assembly Installation • Install the sleeve [A] on the governor assembly [B]. CAUTION First install the sleeve. The sleeve cannot be installed after the governor gear assembly has been installed. • To install, first place the thrust washer [C] on the boss of the shaft [D].
  • Page 38: Carburetor

    3-8 FUEL SYSTEM Carburetor Fuel and Air Flow The main system of the carburetor consists of the main jet [A], valve seat [B] main nozzle [C], and the main air passage [D] (main air jet [E]). The main system meters fuel to the engine during moderate to heavy load conditions.
  • Page 39 FUEL SYSTEM 3-9 Carburetor Dummy Page...
  • Page 40 3-10 FUEL SYSTEM Carburetor The slow system includes the slow jet (pilot jet) [F], idle screw [G] (idle mixture screw), slow air breed jet [H], idle port [I], and the slow port [J]. The slow system meters the fuel/air mixture while the engine is idling and running under a light load.
  • Page 41 FUEL SYSTEM 3-11 Carburetor...
  • Page 42: Low Idle Speed Adjustment

    3-12 FUEL SYSTEM Carburetor Low Idle Speed Adjustment • Refer to the Low Idle Speed Adjustment in the Periodic Maintenance chapter. High Idle Speed Adjustment • Refer to the High Idle Speed Adjustment in the Periodic Maintenance chapter. High Altitude Operation At high altitude, the standard carburetor air-fuel mixture will be excessively rich.
  • Page 43: Fuel System Cleanliness Inspection

    FUEL SYSTEM 3-13 Carburetor • Replace the float chamber gasket with a new one. • Install the float chamber and gasket. • Tighten float chamber mounting bolt [A] as shown the fig- ure. Drain Screw [B] Fuel Inlet Joint [C] Torque - Float Chamber Mounting Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) Fuel system Cleanliness Inspection...
  • Page 44: Carburetor Disassembly/assembly

    3-14 FUEL SYSTEM Carburetor Carburetor Disassembly/Assembly • Refer to the illustration shown for disassembly and as- sembly. • There are several passage plugs (ball plugs) in the car- buretor body. Do not remove. • Before disassembly, mark the out side of choke valve and throttle valves for assembling them.
  • Page 45: Carburetor Cleaning

    FUEL SYSTEM 3-15 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 electrical appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point washing to clean the carburetors.
  • Page 46: Carburetor Inspection

    3-16 FUEL SYSTEM 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 47 FUEL SYSTEM 3-17 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 48: Fuel Pump, Fuel Filter

    3-18 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 Inlet [A] Pulse [B]...
  • Page 49 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Cooling Fan ..........................Cooling Fan Removal ....................... Cooling Fan Installation ....................Cooling Fan Inspection .....................
  • Page 50 4-2 COOLING SYSTEM Exploded View...
  • Page 51 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fan Housing Bolts 0.60 52 in·lb Flywheel Bolt 3. Fan Housing 4. Fan...
  • Page 52: Cooling Fan

    4-4 COOLING SYSTEM Cooling Fan Cooling Fan Removal • Refer to the Flywheel Removal in the Electrical System chapter. Cooling Fan Installation • Refer to the Flywheel Installation in the 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 cool- ing fan.
  • Page 53 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 ......................Push Rod Installation ......................Push Rod Inspection......................Valve Mechanism Removal/Installation ................
  • Page 54: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 55 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Spark Plug Cylinder Head Bolts Connecting Rod Big End Cap Bolts 0.60 52 in·lb Valve Clearance Lock Screws 0.70 61 in·lb Rocker Arm Bolts G: Apply grease. M: Apply molybdenum disulfide grease. O: Apply engine oil.
  • Page 56: Specifications

    5-4 ENGINE TOP END Specifications Item Service Limit Cylinder Head Cylinder Compression (MIN) [294 kPa (43 psi)] (MIN) Cylinder Head Warp 0.03 mm (0.001 in.) Valves Valve Head Thickness: Inlet, Exhaust 0.4 mm (0.016 in.) Valve Stem Runout: Inlet, Exhaust TIR 0.05 mm (0.002 in.) Valve Stem Diameter: Inlet...
  • Page 57: Special Tools

    ENGINE TOP END 5-5 Special Tools Compression Gauge, 20 kgf/cm²: Compression Gauge Adapter, M14 × 1.25: 57001-221 57001-1159 Piston Ring Compressor Belt, 80 ∼ 91: Piston Ring Compressor Grip: 57001-1095 57001-1320...
  • Page 58: Cylinder Head

    5-6 ENGINE TOP END 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 seal compres- sion as it does during normal running.
  • Page 59: Cylinder Head Assembly Removal

    ENGINE TOP END 5-7 Cylinder Head Cylinder Head Assembly Removal • Remove: Cover Bolts [A] and Cover [B] Oil Gauge [C] Carburetor (see Carburetor Removal in the Fuel System chapter) Spark Plug (see Spark Plug Removal in the Electrical System chapter) Fan Housing (see Flywheel Removal in the Electrical System chapter) •...
  • Page 60: Push Rod Removal

    5-8 ENGINE TOP END Cylinder Head • Tighten the cylinder head bolts following the tightening sequence as shown in the figure. Torque - Cylinder Head Bolts: 37 N·m (3.8 kgf·m, 27 ft·lb) CAUTION A torque wrench must be used to assure proper torque.
  • Page 61: Push Rod Inspection

    ENGINE TOP END 5-9 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 [A] on the rod at a point halfway between the blocks. Turn the rod to measure the runout.
  • Page 62: Cleaning And Inspection

    5-10 ENGINE TOP END Cylinder Head Cleaning and Inspection • Refer to the Cylinder Head Cleaning and Inspection in the Periodic Maintenance chapter. Rocker Arm Inspection • Clean and inspect the rocker arm where it touches the push rod and valve stem. If the contact points [A] are worn or damaged, replace the rocker arm.
  • Page 63: Valve Seat Inspection

    ENGINE TOP END 5-11 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 64: Valve Guide Inside Diameter

    5-12 ENGINE TOP END 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 places down the length of the guide. If the measurement is more than the service limit, replace the cylinder head with a new one.
  • Page 65: Cylinder, Piston

    ENGINE TOP END 5-13 Cylinder, Piston Piston Removal • Remove: Crankcase Cover (see Crankcase Cover Removal in the Camshaft/Crankshaft chapter). Camshaft (see Camshaft, Tappet Removal in the Camshaft/Crankshaft chapter). Balancer Shaft (see Balancer Shaft Removal in the Camshaft/Crankshaft chapter). • Turn the crankshaft to expose the connecting rod cap bolts [A].
  • Page 66: Piston Installation

    5-14 ENGINE TOP END 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 67: Piston Cleaning

    ENGINE TOP END 5-15 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 68: Piston Ring And Ring Groove Wear

    5-16 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 69: Piston Ring End Gap

    ENGINE TOP END 5-17 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 70: Piston Diameter

    5-18 ENGINE TOP END Cylinder, Piston Piston Diameter • Measure the outside diameter [A] of the piston 10 mm (0.39 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 71 LUBRICATION SYSTEM 6-1 Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealant ...................... Engine Oil and Oil Filter......................Oil Level Inspection......................Oil Change ........................Oil Filter Replacement ...................... Pressurized Lubrication System ..................... Oil Pressure Measurement ....................
  • Page 72: Exploded View

    6-2 LUBRICATION SYSTEM Exploded View...
  • Page 73 LUBRICATION SYSTEM 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil Filter Joint 0.70 61 in·lb Oil Filter 87 in·lb Oil Drain Plugs 0.70 61 in·lb Crankcase Cover Plug 0.70 61 in·lb Crankcase Cover Bolts 21.6 Cylinder Head Bolts Oil Line Plugs 0.40 35 in·lb...
  • Page 74: Engine Oil Flow Chart

    6-4 LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 75: Specifications

    LUBRICATION SYSTEM 6-5 Specifications Item Standard Engine Oil Type SF, SG, SH or SJ class Viscosity SAE40, SAE30, SAE10W-30/SAE10W-40, or SAE5W-20 Capacity 1.1 L (1.16 US qt) (When filter is not removed) 1.3 L (1.37 US qt) (When filter is removed) Level Operating range (grid area) on dipstick Oil Pressure...
  • Page 76: Special Tools And Sealant

    6-6 LUBRICATION SYSTEM Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Kawasaki Bond (Silicone Sealant): 57001-125 56019-120 Oil Pressure Gauge Adapter, PT 1/8: 57001-1033...
  • Page 77: Oil Level Inspection

    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. Before starting the engine for the first time, add oil: The engine is shipped dry.
  • Page 78: Pressurized Lubrication System

    • Remove the oil pressure gauge and adapter. • Apply silicone sealant to the thread of the oil pressure switch. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Tighten the oil pressure switch. ○ Remove excessive sealant after assembling. If the oil pressure is below the specification, inspect the oil pump and relief valve (see Oil Pump Inspection and Relief Valve Inspection in this chapter).
  • Page 79: Oil Pump, Relief Valve

    LUBRICATION SYSTEM 6-9 Oil Pump, Relief Valve Oil Pump Removal • Remove the crankcase cover (see Crankcase Cover Re- moval in the Camshaft/Crankshaft chapter). • Remove the circlip [A] and oil pump parts assembly (pump cover plate, inner rotor, and outer rotor). CAUTION Do not damage camshaft bore with the circlip.
  • Page 80: Relief Valve Removal

    6-10 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, re- place the crankcase cover. Pump Housing Inside Diameter Service Limit: 40.801 mm (1.6063 in.) •...
  • Page 81: Relief Valve Inspection

    LUBRICATION SYSTEM 6-11 Oil Pump, Relief Valve Relief Valve Inspection • Visually inspect the relief valve spring, steel ball and valve seat in the crankcase. If any rough spots are found during above inspection, wash the valve clean with a high-flash point solvent and blow out any foreign particles that may be in the valve with compressed air.
  • Page 82: Oil Screen

    6-12 LUBRICATION SYSTEM Oil Screen Oil Screen Removal • Remove the crankcase cover (see Crankcase Cover Re- moval in the Camshaft/Crankcase chapter). • Unscrew the mounting bolts [A] and remove the pipe [B]. • Push [C] the oil screen with thumbs and remove it. Oil Screen Installation •...
  • Page 83 CAMSHAFT/CRANKSHAFT 7-1 Camshaft/Crankshaft Table of Contents Exploded View........................Specifications ......................... Special Tool ..........................Crankcase ..........................Crankcase Cover Removal ....................Crankcase Cover Installation .................... Inspection.......................... Cleaning..........................Breather..........................Breather Valve Removal ....................7-10 Breather Valve Installation ....................7-10 Breather Valve Inspection ....................7-10 Camshaft, Tappet ........................
  • Page 84: Exploded View

    7-2 CAMSHAFT/CRANKSHAFT Exploded View...
  • Page 85 CAMSHAFT/CRANKSHAFT 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Valve Clearance Lock Screws 0.70 61 in·lb Rocker Arm Bolts Crankcase Cover Bolts 21.6 Connecting Rod Big End Cap Bolts 0.60 52 in·lb Breather Valve Screw 0.35 30 in·lb G: Apply grease. M: Apply molybdenum disulfide grease.
  • Page 86: Specifications

    7-4 CAMSHAFT/CRANKSHAFT Specifications Item Service Limit Camshaft, Tappet Cam Lobe Height: Inlet 29.86 mm (1.176 in.) Exhaust 29.86 mm (1.176 in.) Camshaft Journal Diameter: PTO Side 49.93 mm (1.966 in.) Flywheel Side 19.97 mm (0.786 in.) Camshaft Bearing Inside Diameter: Crankcase 20.07 mm (0.790 in.) Crankcase Cover...
  • Page 87: Special Tool

    CAMSHAFT/CRANKSHAFT 7-5 Special Tool Bearing Driver Set: 57001-1129...
  • Page 88: Crankcase

    7-6 CAMSHAFT/CRANKSHAFT Crankcase Crankcase Cover Removal • Drain the oil (see Oil Change in the Periodic Maintenance chapter). • Unscrew the mounting bolts [A] and remove the crankcase cover [B] from the crankcase. ○ There are two dowel pins on the crankcase mating sur- face.
  • Page 89: Inspection

    CAMSHAFT/CRANKSHAFT 7-7 Crankcase • Be sure to replace any oil seal removed with a new seal. ○ Install the oil seal so that the marks [A] face out. ○ Pack high temperature grease [B] to 60% volume into the space between the seal lip [C] and dust lip [D]. Press in the new oil seal 4 ∼...
  • Page 90: Cleaning

    7-8 CAMSHAFT/CRANKSHAFT Crankcase Cleaning • Remove: Camshaft and Tappets (see Camshaft, Tappet Removal in this chapter) Crankshaft (see Crankshaft Removal in this chapter) Balancer Shaft (Balancer Shaft Removal in this chapter) • Clean up the crankcase and cover with a high-flash point solvent, and blow out any foreign particles that may be in the pockets inside of the crankcase with compressed air.
  • Page 91: Breather

    CAMSHAFT/CRANKSHAFT 7-9 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 drawn into the clean side of the air cleaner through the crankcase and the cylinder head and mixed with the clean air flow, and subsequently comes into the combustion chamber through the carburetor.
  • Page 92: Breather Valve Removal

    7-10 CAMSHAFT/CRANKSHAFT Breather Breather Valve Removal • Remove the cylinder head assembly (see Cylinder Head Assembly Removal in the Engine Top End chapter). • Unscrew the breather valve screw [A]. Breather Valve Installation • Install the reed valve [A] and back plate [B] , Then tighten the breather valve screw [C].
  • Page 93: Camshaft, Tappet

    CAMSHAFT/CRANKSHAFT 7-11 Camshaft, Tappet Camshaft, Tappet Removal • Drain the oil (see Oil Change in the Periodic Maintenance chapter). • Remove: Crankcase Cover (see Crankcase Cover Removal in this chapter) Rocker Cover [A] • Position the piston TDC at the end of the compression stroke.
  • Page 94: Camshaft Disassembly

    7-12 CAMSHAFT/CRANKSHAFT Camshaft, Tappet • Install the crankcase cover (see Crankcase Cover Instal- lation in this chapter). • Install the push rods (see Push Rod Installation in the Engine Top End chapter). • Mount the rocker arms on the push rods, and install the valve clearance adjusting nuts and the lock screws.
  • Page 95: Camshaft Bearing/journal Wear

    CAMSHAFT/CRANKSHAFT 7-13 Camshaft, Tappet Camshaft Bearing/Journal Wear • Measure the height of each cam lobe [A]. If the cam height is less than the service limit for either lobe, replace the camshaft. Cam Lobe Height Service Limit: Inlet 29.86 mm (1.176 in.) Exhaust 29.86 mm (1.176 in.) •...
  • Page 96: Crankshaft, Connecting Rod

    7-14 CAMSHAFT/CRANKSHAFT Crankshaft, Connecting Rod Connecting Rod Removal • Refer to the Piston Removal in the Engine Top End chap- ter. Connecting Rod Installation • Refer to the Piston Installation in the Engine Top End chapter. Crankshaft Removal • Drain the oil (see Oil Change in the Periodic Maintenance chapter).
  • Page 97: Connecting Rod Bend/twist

    CAMSHAFT/CRANKSHAFT 7-15 Crankshaft, Connecting Rod Connecting Rod Bend/Twist • Measure connecting rod bend. ○ Select an arbor of the same diameter as the connecting rod big end, and insert the arbor through the connecting rod big end. ○ Select an arbor of the same diameter as the piston pin and at least 100 mm long, and insert the arbor through the connecting rod small end.
  • Page 98: Connecting Rod Big End Bearing/crankpin Wear

    7-16 CAMSHAFT/CRANKSHAFT Crankshaft, Connecting Rod Connecting Rod Big End Bearing/Crankpin Wear • Apply a thin film of oil on the thread of the cap bolts. • Install the cap bolts and tighten the bolts to the speci- fied torque (see Piston Installation in the Engine Top End chapter).
  • Page 99: Balancer Shaft

    CAMSHAFT/CRANKSHAFT 7-17 Balancer Shaft Balancer Shaft Removal • Remove: Crankcase Cover (see Crankcase Cover Removal in this chapter). Balancer Shaft [A]. Balancer Shaft Installation • Install the balancer shaft [A] to the balancer shaft bearing on the crankcase. • Install the crankcase cover (see Crankcase Cover Instal- lation in this chapter).
  • Page 101 ELECTRICAL SYSTEM 8-1 Electrical System Table of Contents Exploded View........................Specifications ......................... Special Tool ..........................Wiring Diagram........................Precautions..........................Charging, Ignition System ...................... Flywheel, Stator Coil Removal..................Flywheel, Stator Coil Installation..................Stator Coil Resistance ...................... 8-10 Unregulated Stator Output ....................8-10 Ignition Coil Removal ......................
  • Page 102: Exploded View

    8-2 ELECTRICAL SYSTEM Exploded View...
  • Page 103 ELECTRICAL SYSTEM 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Flywheel Bolt Stator Coil Screws 0.35 30 in·lb Ignition Coil Bolts 0.60 52 in·lb Spark Plug Starter Motor Mounting Bolts G: Apply grease. M: Apply molybdenum disulfide grease. O: Apply engine oil. R: Replacement Parts...
  • Page 104: Specifications

    8-4 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Charging System 0.01 ∼ 0.1 Ω Alternator Stator Coil Resistance – – – Unregulated Stator Output 28.4 V AC/3 000 rpm 26 V AC/3 000 rpm Ignition System Ignition Coil: 0.2 ∼ 0.4 mm (0.0079 ∼ 0.0157 in.) Coil Air Gap –...
  • Page 105: Special Tool

    ELECTRICAL SYSTEM 8-5 Special Tool Hand Tester: 57001-1394...
  • Page 106: Wiring Diagram

    8-6 ELECTRICAL SYSTEM Wiring Diagram...
  • Page 107: Precautions

    ELECTRICAL SYSTEM 8-7 Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ The electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them.
  • Page 108: Charging, Ignition System

    8-8 ELECTRICAL SYSTEM Charging, Ignition System Flywheel, Stator Coil Removal • Remove: Control Panel Assembly (see Control Panel Assembly Removal in the Fuel System chapter) Carburetor (see Carburetor Removal in the Fuel System chapter) • Loosen the fan housing bolts [A] and remove the fan housing [B].
  • Page 109: Flywheel, Stator Coil Installation

    ELECTRICAL SYSTEM 8-9 Charging, Ignition System • Remove: Woodruff Key [A] Stator Coil Screws [B] 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) • Using a cleaning fluid, clean off any oil or dirt on the fol- lowing portions and dry them with a clean cloth.
  • Page 110: Stator Coil Resistance

    8-10 ELECTRICAL SYSTEM Charging, Ignition System ○ Install the washer [A] with its convex surface upward as shown in the figure. Flywheel Bolt [B] • Install the ignition coil (see Ignition Coil Installation in this chapter). • Install the fan housing and tighten the bolts. Torque - Fan Housing Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) •...
  • Page 111 ELECTRICAL SYSTEM 8-11 Charging, Ignition System This engine ignition is controlled by a solid state ignition assembly and requires no periodic main- tenance except for the spark plug. The system consists of the following: Inductive Ignition Assembly Permanent Magnet Flywheel Spark Plug Stop Switch B: Base...
  • Page 112: Ignition Coil Removal

    CAUTION Use only Tester 57001-1394 with new battery at room temperature for this test. A tester other than the Kawasaki Hand Tester may show different read- ings. If a meter with a large-capacity battery is used, the ignition coil will be damaged.
  • Page 113: Spark Plug Cleaning And Gap Inspection

    ELECTRICAL SYSTEM 8-13 Charging, Ignition System Spark Plug Installation • Screw the spark plug gently into the plug hole with the plug installed in the plug wrench. • Tighten the plugs. Torque - Spark Plug: 22 N·m (2.2 kgf·m, 16 ft·lb) •...
  • Page 114: Electric Starter System

    8-14 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal • Disconnect the wires shown [A]. • Remove the mounting bolts [B] and pull the starter motor from the engine with the switch lead [C] attached. Starter Motor Installation • Clean the starter motor and engine mounting flanges to ensure good electrical contact and tighten the mounting bolts.
  • Page 115: Starter Motor Test

    ELECTRICAL SYSTEM 8-15 Electric Starter System • Set the hand tester to the R × 1 Ω position and connect the leads as shown. Switch Terminal [A] To Ground [B] If the tester does not read close to 0 Ω, the solenoid is faulty.
  • Page 116: Starter Motor Disassembly

    8-16 ELECTRICAL SYSTEM Electric Starter System Starter Motor Disassembly • Remove the lead [A] from the starter motor to the sole- noid. • Unscrew the mounting nuts [A] and remove the solenoid assembly [B]. • Remove: Through Bolts [A] Pinion Gear Cover [B] •...
  • Page 117: Starter Motor Assembly Notes

    ELECTRICAL SYSTEM 8-17 Electric Starter System • Separate the front stopper [A] and rear stopper [B] each other and remove the front stopper to left side [C] as shown in the figure. • Push the rear stopper to right side [D] and remove the snap ring [E] as shown in the figure.
  • Page 118 8-18 ELECTRICAL SYSTEM Electric Starter System • Inspect the rubber insert [A] and/or boot [B] for visible damage. If they are damaged, replace them. • Fit the notch [A] in the (–) lead grommet onto the projec- tion [B] on the end cover [C]. •...
  • Page 119: Starter Motor Brush Inspection

    ELECTRICAL SYSTEM 8-19 Electric Starter System Starter Motor Brush Inspection • Measure the overall length of each brush [A]. If the brushes are shorter than the service limit, replace them. Carbon Brush Length Standard: 10 mm (0.394 in.) Service Limit: 6.0 mm (0.236 in.) Brush Spring Inspection •...
  • Page 120 8-20 ELECTRICAL SYSTEM Electric Starter System • Measure the commutator [B] outside diameter [A] at sev- eral points. If the diameter is less than the service limit, replace the armature with a new one. Commutator Outside Diameter Standard: 28 mm (1.102 in.) Service Limit: 27 mm (1.063 in.) •...
  • Page 121: Yoke Assembly Inspection

    ELECTRICAL SYSTEM 8-21 Electric Starter System Yoke Assembly Inspection • Set the multimeter selector switch to the R × 1 kΩ position and measure the resistance between the positive brushes and stator motor yoke. If the resistance is less than infinite, the positive brush is shorted to ground.
  • Page 123 TROUBLESHOOTING 9-1 Troubleshooting Table of Contents Engine Troubleshooting Guide ....................Starter Motor Troubleshooting Guide ..................
  • Page 124 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 the malfunction.
  • Page 125 TROUBLESHOOTING 9-3 Engine Troubleshooting Guide...
  • Page 126 9-4 TROUBLESHOOTING Engine Troubleshooting Guide...
  • Page 127 TROUBLESHOOTING 9-5 Engine Troubleshooting Guide...
  • Page 128 9-6 TROUBLESHOOTING Starter Motor Troubleshooting Guide 1. Disconnect spark plug cap, and ground the cap terminal. 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 129 Part No.99924-2066-01 Printed in Japan...

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  • #1039163 May 11, 2018 12:20:
    Excellent manual thanks FJ. 400D