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Kawasaki FH451V Service Manual

4-stroke air cooled v-twin gasoline engine.
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4–stroke air cooled v-twin gasoline engine
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of
Quality Assurance Department/Consumer Products & Machinery Group/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been
taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such
changes to products manufactured previously.
All information contained in this publication is based on the latest product information available at the time of publication.
Illustrations and photographs in this publication are intended for reference use only and may not depict actual model
component parts.
© Kawasaki Heavy Industries, Ltd., 1999, 2000
FH451V,FH500V,FH531V
FH601V,FH641V,FH680V
FH721V
Third Edition (1) : Nov. 20, 2000 (K)

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Table of Contents

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   Summary of Contents for Kawasaki FH451V

  • Page 1 Quality Assurance Department/Consumer Products & Machinery Group/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.
  • Page 2 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch degree(s) Celsius revolution direct current revolution(s) per minute...
  • Page 3: Emission Control Information

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

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

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing.................................1-2 Model Identification ................................1-4 General Specifications ............................... 1-6 Periodic Maintenance Chart...............................1-7 Torque and Locking Agent ..............................1-9 Special Tools ..................................1-13...
  • Page 6: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to service the engine, carefully read the applicable section to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is required for successful work. Especially note the following: (1) Dirt Before removal and disassembly, clean the engine.
  • Page 7: General Information

    GENERAL INFORMATION 1-3 Before Servicing (15) Cotter Pin Replace any cotter pins that were removed with new ones, as removal deforms and breaks them. (16) Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film.
  • Page 8: Model Identification

    1-4 GENERAL INFORMATION Model Identification Electric Starter Model-FH500V Recoil Starter Model-FH500V Cylinder Number Designation: No.1 Cylinder is the left-hand cylinder viewed from the air cleaner. No.2 Cylinder is the right-hand cylinder viewed from the air cleaner.
  • Page 9 GENERAL INFORMATION 1-5 Model Identification Electric Starter Model-FH680V...
  • Page 10: General Specifications

    1-6 GENERAL INFORMATION General Specifications Items FH451V, FH500V, FH531V FH601V, FH641V, FH680V FH721V Type of engine Forced air-cooled, vertical shaft, OHV, 4-stroke gasoline engine. Cylinder layout 90 V-Twin Bore x Stroke 68 mm x 68 mm (2.68 in x 2.68 in) 75.2 mm x 76 mm (2.96 in x 2.99 in)
  • Page 11: 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 12 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 13: Torque And Locking Agent

    M : Apply a molybdenum disulfide lubricant (grease or oil) to the threads, seated surface, or washer. O : Apply an oil to the threads, seated surface, or washer. S : Tighten the fasteners following the specified sequence. SS : Apply silicone sealant. FH451V, FH500V, FH531V FH451V, FH500V, FH531V Fastener Remarks...
  • Page 14 1-10 GENERAL INFORMATION Torque and Locking Agent FH451V, FH500V, FH531V Fastener Remarks Torque Lubrication System: Engine Drian Plugs (Plastic) 0.70 61 in Engine Drain Plug (Metal) 14.5 Engine Drain Plug Joint (Plastic) 12.0 Engine Drain Plug Joint (Metal) Oil Pressure Switch...
  • Page 15 GENERAL INFORMATION 1-11 Torque and Locking Agent FH601V, FH641V, FH680V, FH721V FH601V, FH641V, FH680V, FH721V Fasteners Remarks Torque Fuel System: Choke Valve Screw 0.10 8.9 in Throttle Valve Screws 0.10 8.9 in Pilot Jet – – – Main Jet – –...
  • Page 16 1-12 GENERAL INFORMATION Torque and Locking Agent FH601V, FH641V, FH680V, FH721V Fastener Remarks Torque Lubrication System: Engine Drian Plugs (Plastic) 61 in Engine Drain Plug (Metal) 14.5 Engine Drain Plug Joint (Plastic) Engine Drain Plug Joint (Metal) Oil Pressure Switch 87 in = SS Oil Passage Plug...
  • Page 17: Special Tools

    GENERAL INFORMATION 1-13 Special Tools Compression Gauge: 57001–221 Valve Seat Cutter Holder Ø6: 57001–1360 Piston Ring Pliers: 57001–115 Valve Seat Cutter, 45 - Ø35.0: 57001–1116 Piston Ring Compression Grip: 57001–1095 Valve Seat Cutter, 30 - Ø 33.0: 57001–1199 Piston Ring Compression Belt, Ø67 -Ø79: 57001–1097 Compression Gauge Adapter M14 x 1.25: 57001–1159 Valve Seat Cutter Holder Bar: 57001–1128 Valve Seat Cutter, 30...
  • Page 18 1-14 GENERAL INFORMATION Special Tools Oil Filter Wrench : 57001–1249 Kawasaki Bond (Silicone Sealant) : 56019–120 Hand Tester: 57001–1394...
  • Page 19 Fuel Filter Inspection..........2-24 Governor Shaft Installation.........2-11 Air Cleaner..............2-25 Carburetor..............2-12 Element Removal - FH451V, 500V, 531V ..2-25 Fuel and Air Flow ..........2-12 Element Removal - FH601V, 641V, 680V, 721V 2-25 Fuel Shut Off Solenoid Valve (Electric Starter Element Installation ..........2-25 Model)..............2-13...
  • Page 20: Exploded View

    2-2 FUEL SYSTEM Exploded View [FH451V, FH500V, FH531V]...
  • Page 21 FUEL SYSTEM 2-3 Exploded View [FH451V, FH500V, FH531V] 1. Pilot Screw 2. Pilot Air Jet 3. Main Air Jet 4. Main Jet 5. Pilot Jet 6. Solenoid Valve T1: 0.7 N m (0.07 kg m, 6 in T2: 1.0 N m (0.10 kg...
  • Page 22 2-4 FUEL SYSTEM Exploded View [FH601V, FH641V, FH680V, FH721V]...
  • Page 23 FUEL SYSTEM 2-5 Exploded View [FH601V, FH641V, FH680V, FH721V] 1. Pilot Screw 2. Pilot Air Jet 3. Main Air Jet 4. Main Jet 5. Pilot Jet 6. Solenoid Valve T1: 1.0 N m (0.10 kg m, 9 in T2: 3.9 N m (0.40 kg m, 35 in T3: 2.0 N...
  • Page 24 2-6 FUEL SYSTEM Exploded View...
  • Page 25 FUEL SYSTEM 2-7 Exploded View [FH451V, FH500V, FH531V] T5: 2.0 N m (0.20 kg m , 17 in T8: 5.9 N m (0.60 kg m , 52 in T9: 7.8 N m (0.80 kg m , 69 in [FH601V, FH641V, FH680V, FH721V] T5: 2.0 N...
  • Page 26: Specifications

    2-8 FUEL SYSTEM Specifications Standard FH601V, FH641V, FH680V, FH451V, FH500V, FH531V Item FH721V Caburetors Specifications: Make/ type MIKUNI B24T1 Nikki 621266 Throttle bore diameter 24 mm (0.94 in.) 26 mm (1.02 in.) Venturi diameter 16 mm (0.63 in.) 18 mm (0.71 in.) 21 mm (0.83 in.)
  • Page 27: Governor Link Mechanism

    FUEL SYSTEM 2-9 Governor Link Mechanism Control Panel Assembly Removal • Remove: Air Cleaner (see Cleaner Body Removal) Air Cleaner Mount Bracket Bolts [A] Air Cleaner Mount Bracket [B] Earth Lead (Starter Model) Control Panel Mounting Bolts [C] • Remove the control panel assembly [A] while unhooking the governor spring [B] end loop at the panel bracket.
  • Page 28: Governor Arm Installation

    2-10 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 inplace and that it pulls the governor arm and throttle lever [E] each other. •...
  • Page 29: Governor Assembly Inspection

    FUEL SYSTEM 2-11 Governor Link Mechanism Governor Assembly Inspection Visually check all governor parts for wear and damage. If any parts are worm or damaged, replace them. Governor Shaft Removal • Split the crankcase (see Camshaft/Crankcase chapter). • Unscrew the governor shaft plate screws [A], and pull out the governor shaft [B] outside.
  • Page 30: Carburetor

    2-12 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 31: Fuel Shut Off Solenoid Valve (electric Starter Model)

    (turn the governor arm clockwise all the way) and adjust the low idle speed screw [A] until the engine idles at specified speed. - FH451V, 500V, 531V. • Adjust the low idle speed screw [C] with Phillips Screwedriver [D] until the engine idles at specified speed.–...
  • Page 32: High Altitude Operation

    The main jet high altitude kits are available if the equipment is to be used in the high altitudes. The main jet numbers are stamped on ends of the main jets. High Altitude Main Jet Main Jet No Altitude FH451V, FH531V FH601V, FH500V FH641V, FH680V,...
  • Page 33: Fuel System Cleanliness Inspection

    • Tighten the main jet to the specification (see Carburetor Disassembly Assembly Notes). • Install the float chamber, gasket and solenoid valve.– FH451V, 500V, 531V • Remove the carburetor (see Carburetor Removal). •...
  • Page 34: Carburetor Removal

    • Unhook the throttle [D] and choke link rods [E] at the top ends of their arms while pull off the carburetor - FH451V, 500V, 531V • Unhook the throttle link spring [B] at the link clip [F] with a long nose plier.
  • Page 35: Carburetor Disassembly/assembly - Fh451v, 500v, 531v

    FUEL SYSTEM 2-17 Carburetor Carburetor Disassembly/Assembly - FH451V, 500V, 531V • Refer to the illustration shown for disassembly and assembly. • There are several passage plugs (Ball plugs) in the carburetor body. Do not remove. • Before disassembly, mark the out side of choke valve and throttle valves for assembling them.
  • Page 36: Carburetor Disassembly/assembly-fh601v, 641v, 680v, 721v

    2-18 FUEL SYSTEM Carburetor Carburetor Disassembly/Assembly- FH601V, 641V, 680V, 721V. • Refer to the illustration shown for disassembly and assembly. • There are several passage plugs (Ball plugs) in the carburetor body. Do not remove. • Before disassembly, mark the out side of choke valve and throttle valves for assembling them.
  • Page 37: Carburetor Cleaning

    FUEL SYSTEM 2-19 Carburetor • Drive the float pin so that it’s big diameter side faces the throttle shaft lever side. • The fuel inlet valve seat is pressed into the carburetor body and is not replacable. • Assemble carburetor parts which recommended tightening torque. (see Exploded View) Carburetor Cleaning Clean the carburetor in a well-ventilated area, and take care...
  • Page 38: Carburetor Inspection

    2-20 FUEL SYSTEM Carburetor Carburetor Inspection Gasoline is extremely flammable and can be explosive under certain. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. •...
  • Page 39: Fuel Shut-off Solenoid Valve Test (electricstarter Model)

    FUEL SYSTEM 2-21 Carburetor Fuel Shut-Off Solenoid Valve Test (Electric Starter Model) • Unscrew the fuel shut off valve and remove the valve. • Connect a 12 VDC source to the solenoid as shown. If the actuate solenoid plunger (Needle Valve) does not pop in when the Test Voltage is applied, replace it.
  • Page 40: Intake Manifold

    • Clean the mating surfaces of the cylinders and intake manifolds and fit a new gaskets [A] direction as shown. [B] Distance (FH451V, 500V, 531V): 6 mm [B] Distance (FH601V, 641V, 680V, 721V): 12 mm • Clean the mating surfaces of the carburetor and intake manifold and install the new gaskets [A] and insulator [B] sequence as shown.
  • Page 41: Intake Manifold Inspection

    FUEL SYSTEM 2-23 Intake Manifold Intake Manifold Inspection • Inspect the intake manifold for cracks or porous casting. • Cracks not visible to the eye may be detected by coating the suspected area with mixture of 25% kerosene and 75% light engine oil.
  • Page 42: Fuel Pump, Fuel Filter

    2-24 FUEL SYSTEM Fuel Pump, Fuel Filter The fuel pump cannot be disassembled, if any damage for the pump is noticed replace it with a new one. Fuel Pump Inspection • Check the vent hole [A] and filter [B] for plugging or clogging. If vent hole and filter are plugged or clogged, remove the foreign matter from them.
  • Page 43: Air Cleaner

    Be sure the paper element is in-place in the air cleaner body. • Be sure the foam element is in-place on the paper element body. Element Cleaning and Inspection - FH451V, 500V, 531V NOTE In dusty areas, the elements should be cleaned more frequently than the recommended intervals.
  • Page 44: Element Cleaning And Inspection - Fh601v, 641v, 680v, 721v

    Do not use compressed air to clean the paper element. Do not oil the paper or foam element. Element Cleaning and Inspection - FH601V, 641V, 680V, 721V • See Element Cleaning and Inspection - FH451V, 500V, 531V Foam Element [A] Paper Element [B] Cleaner Body Removal - FH451V, 500V, 531V •...
  • Page 45: Cleaner Body Removal - Fh601v, Fh641v, Fh680v, Fh721v

    Loosen nuts [C] and remove the solenoid valve wire [D]. • Unscrew the bolts [E] and remove the intake pipe [F]. Cleaner Body Installation - FH451V, 500V, 531V • Connect the breather tube from the crankcase to the pipe at the back of the cleaner body.
  • Page 46: Housing (case And Body) Inspection

    2-28 FUEL SYSTEM Air Cleaner Housing (Case and Body) Inspection • Clean the housing with detergent and water and dry thoroughly. • Check the housing for deformation or other damage. The housing must seal well and permit only filtered air to reach the carburetor. If the housing is damaged, it must be replaced.
  • Page 47 COOLING SYSTEM 3-1 Cooling System Table of Contents Exploded View..................................3-2 Cooling Fan..................................3-4 Cooling Fan Removal..............................3-4 Cooling Fan Installation...............................3-4 Cooling Fan Inspection..............................3-4 Screen Clearance Adjustment.............................3-5...
  • Page 48: Exploded View

    3-2 COOLING SYSTEM Exploded View...
  • Page 49: Cooling System

    COOLING SYSTEM 3-3 Exploded View [FH451V, FH500V, FH531V] T1: 3.9 N m (0.40 kg m, 35 in T2: 5.9 N m (0.60 kg m, 52 in T3: 17 N m (1.7 kg m, 12.0 ft T4: 56 N m (5.7 kg m, 41 ft T5: 7.8 N...
  • Page 50: Cooling Fan

    3-4 COOLING SYSTEM Cooling Fan Cooling Fan Removal • Refer to Flywheel Removal in Electrical System chapter. Cooling Fan Installation • Refer to Flywheel Installation in Electrical System chapter. Cooling Fan Inspection • Visually inspect the blades [A] in the cooling fan [B]. If they are any cracks, warps or damaged, replace the cooling fan.
  • Page 51: Screen Clearance Adjustment

    COOLING SYSTEM 3-5 Cooling Fan Screen Clearance Adjustment • Check clearance between screen [A] and fan housing [B]. If clearance is less than 1 mm, add proper number of spacer [C] between screen and bracket comp [D] to adjust clearance [G] 1 3 mm.
  • Page 53 ENGINE TOP END 4-1 Engine Top End Table of Contents Exploded View..................................4-2 Specifications ..................................4-6 Cylinder Head..................................4-9 Compression Measurement ............................4-9 Cylinder Head Assembly Removal..........................4-10 Cylinder Head Assembly Installation.........................4-10 Push Rod Removal..............................4-11 Push Rod Installation ..............................4-11 Push Rod Inspection..............................4-12 Valve Mechanism Removal/Installation........................4-12 Cleaning and Inspection............................4-13 Valves....................................
  • Page 54: Exploded View

    4-2 ENGINE TOP END Exploded View...
  • Page 55: Engine Top End

    ENGINE TOP END 4-3 Exploded View [FH451V, FH500V, FH531V] T1: 5.9 N m (0.60 kg m, 52 in T2: 5.9 N m (0.60 kg m, 52 in T3: 25 N m (2.6 kg m, 19.5 ft T4: 28 N m (2.8 kg...
  • Page 56 4-4 ENGINE TOP END Exploded View...
  • Page 57 ENGINE TOP END 4-5 Exploded View [FH451V, FH500V, FH531V] T2: 15 N m (1.5 kg m, 11.0 ft [FH601V, FH641V, FH680V, FH721V] T2: 15 N m (1.5 kg m, 11.0 ft...
  • Page 58: Specifications

    4-6 ENGINE TOP END Specifications Item Service Limit FH451V, FH500V, FH531V Cylinder Head: Cylinder compression (MIN) [390 kPa (57 psi)] (MIN) Cylinder head warp 0.05 mm (0.002 in.) Valves: Valve head thickness Intake, Exhaust 0.35 mm (0.014 in.) Valve stem runout Intake, Exhaust 0.05 mm (0.002 in.)
  • Page 59 ENGINE TOP END 4-7 Specifications Item Service Limit FH601V, FH641V, FH680V, FH721V Cylinder Head: Cylinder compression (MIN) [390 kPa (57 psi)] (MIN) Cylinder head warp 0.05 mm (0.002 in.) Valves: Valve head thickness Intake, Exhaust 0.35 mm (0.014 in.) Valve stem runout Intake, Exhaust 0.05 mm (0.002 in.) Valve stem diameter...
  • Page 60: Compression Gauge Adapter M14 X 1.25:

    4-8 ENGINE TOP END Specifications Special Tools - Compression Gauge : 57001 - 221 Compression Gauge Adapter M14 x 1.25: 57001–1159 Piston Ring Pliers: 57001 - 115 Piston Ring Compression Grip: 57001 - 1095 Piston Ring Compression Belt, 67 - 79: 57001–1097 Valve Seat Cutter Holder Bar: 57001–1128 Valve Seat Cutter Holder, 6: 57001–1360...
  • Page 61: Cylinder Head

    ENGINE TOP END 4-9 Cylinder Head Compression Measurement • Before measuring compression, do the following. Be sure the battery is fully charged. Thoroughly warm up the engine so that engine oil between the piston and cylinder wall will help seal compression as it does during normal running.
  • Page 62: Cylinder Head Assembly Removal

    4-10 ENGINE TOP END Cylinder Head Cylinder Head Assembly Removal • Remove: Air Cleaner and Carburetor (see Fuel System chapter) Muffler (see Muffler Exhaust Pipe Removal) Intake Manifold (see Fuel System chapter) Spark Plug • Unscrew the rocker cover mounting bolts [A], and remove the cover [B] and gasket.
  • Page 63: Push Rod Removal

    ENGINE TOP END 4-11 Cylinder Head • Tighten the cylinder head bolts following the tightening sequence. Torque - Cylinder Head Bolts: 25 N m (2.6 kg m, 19.0 ft CAUTION A torque wrench must be used to assure proper torque. Improper tightening of the head bolts can result in warping of the cylinder head.
  • Page 64: Push Rod Inspection

    4-12 ENGINE TOP END Cylinder Head Push Rod Inspection • Place the rocker arm push rod in V blocks that are as far apart as possible, and set a dial gauge on the rod at a point halfway between the blocks. Turn the rod to measure the runout. The difference between highest and the lowest dial readings is the amount of runout.
  • Page 65: Cleaning And Inspection

    ENGINE TOP END 4-13 Cylinder Head Cleaning and Inspection • Scrape the carbon deposits from the head and exhaust port with a suitable tool [A]. • To avoid gouging, use scrapers that are made of a material that will not cause damage. •...
  • Page 66: Valves

    4-14 ENGINE TOP END Valves Valve Clearance Inspection NOTE Valve clearance must be checked when the engine is cold (at room temperature). • Remove the rocker cover (see Cylinder Head Removal). • Place the piston at top dead center (TDC) of the compression stroke turning the crankshaft clockwise facing the flywheel.
  • Page 67: Valve Seat Inspection

    The valve stem and guide must be in good condition or this check will not be valid. If the valve seating pattern is not correct, repair the seat. Valve Seating Surface Width (STD) [FH451V, FH500V, FH531V] Inlet, Exhaust 0.9 mm (0.024 0.035 in.)
  • Page 68 4-16 ENGINE TOP END Valves 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 69: Valve Head Thickness

    ENGINE TOP END 4-17 Valves • Use a 30 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 30 cutter removes material very quickly.
  • Page 70: Valve Stem Runout

    4-18 ENGINE TOP END Valves Valve Stem Runout • Support the valve in V blocks at each end of the stem. • Position a dial gauge perpendicular to the stem. • Turn the valve and read the variation on the dial gauge. If the stem runout is greater than service limit, replace the valve.
  • Page 71: Cylinder, Piston

    ENGINE TOP END 4-19 Cylinder, Piston Piston Removal • Split the crankcase (see Camshaft/Crankshaft chapter). • Remove the camshaft (see Camshaft/Crankshaft chapter). • Turn the crankshaft to expose the connecting rod cap bolts [A]. • Remove the bolts and take off the connecting rod caps [B]. NOTE Note the position of the connecting rod caps for reinstalling the caps.
  • Page 72: Piston Installation

    Install the second and top rings as shown. The rings should turn freely in the grooves. [A] Piston Head [B] Top Ring for FH451V, 500V, 531V [C] Second Ring for FH451V, 500V, 531V [D] Top Ring for FH601V, 641V, 680V, 721V [E] Second Ring for FH601V, 641V, 680V, 721V •...
  • Page 73: Piston/cylinder Seizure

    Apply a small amount of engine oil to the thread [D] and seating surface [E] of the cap bolts. • Tighten the cap bolts. Torque - [FH451V, 500V, 531V] Connecting Rod Big End Cap Bolts: 5.9 N m (0.60 kg m, 52 [FH601V, 641V, 680V, 721V] Connecting Rod Big End Cap Bolts: 21 N m (2.1 kg...
  • Page 74: Piston Cleaning

    [A]. If the piston ring/groove clearance is greater than the specified value, replace the piston. Piston Ring/Groove Clearance Service Limit FH451V, FH500V, FH531V FH601V, FH641V, FH680V, FH721V 0.15 mm (0.006 in.) 0.18 mm (0.007 in.) Second 0.12 mm (0.005 in.)
  • Page 75: Piston Ring End Gap

    If the end gap of any ring is greater than the service limit, replace the entire set of rings. Piston Ring End Gap Service Limit FH451V, FH500V, FH531V FH601V, FH641V, FH680V, FH721V 0.70 mm (0.028 in.) 0.65 mm (0.026 in.) Second 0.78 mm (0.031 in.)
  • Page 76: Piston Diameter

    If the measurement is less than the service limit, replace the piston. Piston Diameter Model Service Limit FH451V, FH500V, FH531V 67.79 mm (2.669 in.) FH601V, FH641V, FH680V, FH721V 74.99 mm (2.952 in.) Cylinder Inside Diameter •...
  • Page 77: Cylinder Boring And Honing

    Use the stone recommended by the hone manufactures to produce correct cylinder wall finish. Machine-bore first, the bore diameters should be shown in the table. Final Boring Bore Diameter Oversize Fine Boring Bore Diameter FH451V, 500V, 531V FH601V, 641V, 680V, 721V 0.50 mm 68.46 68.48 mm 75.65 75.68 mm...
  • Page 78 4-26 ENGINE TOP END Cylinder, Piston CAUTION Stop the drill press before measuring and remove the hone from the cylinder. NOTE The finish should not be smooth, but have a 40 to 60 degree crosshatch pattern. • Hone the cylinder until it is about 0.007 to 0.009 mm (0.0003 to 0.0004 in) large to allow for shrinkage when the cylinder cools.
  • Page 79: Muffler/exhaust Pipe Installation

    ENGINE TOP END 4-27 Muffler/Exhaust Pipe Installation Muffler/Exhaust Pipe Removal • Loosen the clamp nut [A]. • Remove the bolt [B] on the muffler bracket and take off the muffler. • Unscrew the exhaust pipe flange nuts [A], and remove the exhaust pipe [B] with pipe cover [C].
  • Page 81 LUBRICATION SYSTEM 5-1 Lubrication System Table of Contents Exploded View..................................5-2 Engine Oil Flow Chart................................5-4 Specifications ..................................5-5 Engine Oil, Oil Filter, and Oil Cooler..........................5-6 Oil Level Inspection ..............................5-6 Oil Change...................................5-6 Oil Filter Removal................................5-7 Oil Filter Installation..............................5-7 Oil Cooler Removal ..............................5-7 Oil Cooler Installation..............................5-7 Pressurized Lubrication System............................5-8 Oil Pressure Measurement............................5-8...
  • Page 82: Exploded View

    5-2 LUBRICATION SYSTEM Exploded View...
  • Page 83: Lubrication System

    LUBRICATION SYSTEM 5-3 Exploded View [FH451V, FH500V, FH531V] T1: 3.9 N m (0.40 kg m, 35 in T2: 6.9 N m (0.7 kg m, 61 in T3: 9.8 N m (1.0 kg m, 87 in T4: 20 N m (2.0 kg m, 14.5 ft...
  • Page 84: Engine Oil Flow Chart

    5-4 LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 85: Specifications

    Pump shaft outside diameter 10.923 mm (0.4300 in.) Pump shaft bearing inside diameter 11.072 mm (0.4359 in.) Relief valve spring free length 19.50 mm (0.77 in.) Special Tool - Oil Filter Wrench : 57001–1249 Sealant - Kawasaki Bond (Silicone Sealant) : 56019–120...
  • Page 86: Engine Oil, Oil Filter, And Oil Cooler

    5-6 LUBRICATION SYSTEM Engine Oil, Oil Filter, and Oil Cooler CAUTION Engine operation with insufficient, deteriorated, or contami- nated engine oil will cause accelerated wear and may result in engine seizure and accident. Before starting the engine for the first time, add oil: The engine is shipped dry.
  • Page 87: Oil Filter Removal

    LUBRICATION SYSTEM 5-7 Engine Oil, Oil Filter, and Oil Cooler • Remove the oil filler cap and pour in the specified type and amount of oil. Engine Oil : Grade: SF, SG, SH or SJ Class Viscosity: SAE40, SAE30, SAE10W-30/SAE10W-40, or SAE5W-20 Capacity: [When filter is not removed]...
  • Page 88: Pressurized Lubrication System

    • Apply silicone sealant to the threads of the pressure switch and tighten it, or tighten the plug. Sealant - Kawasaki Bond (Silicone Sealant) : 56019–120 Torque - Oil Pressure Switch : 9.8 N m (1.0 kg m, 87 in Oil Passage Plug : 3.9 N...
  • Page 89: Oil Pump, Relief Valve

    LUBRICATION SYSTEM 5-9 Oil Pump, Relief Valve Oil Pump, Relief Valve Removal • Remove the crankcase cover (see Camshaft/Crankshaft chapter). • Unscrew the mounting bolts and remove the oil pump parts assembly (pump gear, pump cover plate, pump shaft, pins and rotors). •...
  • Page 90 5-10 LUBRICATION SYSTEM Oil Pump, Relief Valve • Measure the inside diameter [A] of the pump housing with a inside micrometer at several points. If the inside diameter is more than the service limit, replace the crankcase cover. Pump Housing Inside Diameter Service Limit: 40.801 mm (1.6063 in.) •...
  • Page 91 LUBRICATION SYSTEM 5-11 Oil Pump, Relief Valve If cleaning does not solve the problem, replace the relief valve parts. If necessary, put the ball in position and lightly tap the ball with a suitable tools to form a perfect seat. •...
  • Page 92: Oil Screen

    5-12 LUBRICATION SYSTEM Oil Screen Oil Screen Removal • Remove the crankcase cover (see Camshaft/Crankcase chapter). • Unscrew the mounting bolts [A] and remove the oil pump parts assembly. • Remove the oil screen [B]. Oil Screen Installation • Clean the oil screen thoroughly whenever it is removed for any reason. •...
  • Page 93 Crankcase Cover Installation............................6-5 Inspection ..................................6-6 Cleaning..................................6-7 Breather....................................6-8 Breather Element Removal - FH451V, 500V, 531V ....................6-9 Breather Element Installation - FH451V, 500V, 531V....................6-9 Breather Valve Inspection - FH601V, 641V, 680V, 721V ...................6-9 Camshaft, Tappet ................................6-10 Camshaft, Tappet Removal ............................6-10 Camshaft, Tappet Installation............................6-10...
  • Page 94: Exploded View

    6-2 CAMSHAFT/CRANKSHAFT Exploded View...
  • Page 95 CAMSHAFT/CRANKSHAFT 6-3 Exploded View [FH451V, FH500V, FH531V] T1: 5.9 N m (0.6 kg m, 52 in T2: 25 N m (2.6 kg m, 19.0 ft T3: See Engine Top End chapter. [FH601V, FH641V, FH680V, FH721V] T1: 5.9 N m (0.6 kg...
  • Page 96: Specifications

    39.896 mm (1.571 in.) Crankcase: PTO shaft bearing inside diameter Crankcase Cover 35.15 mm (1.384 in.) 40.15 mm (1.581 in.) Crankshaft journal bearing inside diameter Crankcase 35.15 mm (1.384 in.) 40.15 mm (1.581 in.) Sealant - Kawasaki Bond (Silicone Sealant): 56019–120...
  • Page 97: Crankcase

    CAMSHAFT/CRANKSHAFT 6-5 Crankcase Crankcase Cover Removal • Set the engine on a clean surface while parts are being removed. • Drain the oil (see Lubrication System chapter). • Remove: Exhaust Pipe and Muffler (see Engine Top End chapter) Control Panel (see Fuel System chapter) Governor Arm (see Fuel System chapter) •...
  • Page 98: Inspection

    • Install the gasket on the crankcase. • Install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence shown - FH451V, 500V, 531V. Torque - Crankcase Cover Bolts: 25 N m (2.6 kg m, 19.0 ft Do not turn one screw down completely before the others, as it may cause the crankcase cover to warp.
  • Page 99: Cleaning

    CAMSHAFT/CRANKSHAFT 6-7 Crankcase Cleaning • Remove: Camshaft and Tappets (see Camshaft, Tappet Removal) Crankshaft (see Crankshaft Removal) • 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 100: Breather

    6-8 CAMSHAFT/CRANKSHAFT Breather The function of the breather is to create a vacuum in the crankcase which prevents oil from being forced out of the engine through the piston rings, oil seals or gaskets. A sealed-type crankcase emission control system is used to eliminate blow-by gases.
  • Page 101: Breather Element Removal - Fh451v, 500v, 531v

    CAMSHAFT/CRANKSHAFT 6-9 Breather Breather Element Removal - FH451V, 500V, 531V • Remove the bolts [A] and breather chamber cover [B]. • Remove the element [A]. • Check to see that the plate [B] is in place under the element [A].
  • Page 102: Camshaft, Tappet

    6-10 CAMSHAFT/CRANKSHAFT Camshaft, Tappet Camshaft, Tappet Removal • Set the engine on a clean surface while parts are being removed. • Drain the oil (see Lubrication System chapter). • Remove: Muffler (see Engine Top End chapter) Throttle Control Panel (see Fuel System chapter) Carburetor (see Fuel System chapter) Intake Manifold (see Fuel System chapter) Crankcase Cover (see Crankcase Cover Removal)
  • Page 103: Camshaft Disassembly

    If the cam height is less than the service limit for either lobe, replace the camshaft. Cam Lobe Height Model Service Limit FH451V, 500V, 531V IN. 29.131 mm (1.1469 in.) EX. 29.131 mm (1.1469 in.) FH601V, 641V, 680V, 721V IN. 29.621 mm (1.166 in.)
  • Page 104 6-12 CAMSHAFT/CRANKSHAFT Camshaft, Tappet • Measure both camshaft journals at several points around the journal circumference. If the journal diameter is less than the service limit, replace the camshaft. PTO Side Camshaft Journal Diameter Service Limit: 15.985 mm (0.6293 in.) Flywheel Side Camshaft Journal Diameter Service Limit: 15.985 mm (0.6293 in.)
  • Page 105: Crankshaft, Connecting Rod

    CAMSHAFT/CRANKSHAFT 6-13 Crankshaft, Connecting Rod Connecting Rod Removal • Remove: Piston (see Engine Top End Chapter) Connecting Rod Installation • Install: Piston (see Engine Top End chapter) Crankshaft Removal • Set the engine on a clean surface while parts are being removed. •...
  • Page 106: Connecting Rod Big End/crankpin Width Wear

    If the measurement is less than the service limit, replace the connecting rod. Connecting Rod Big End Width Model Service Limit FH451V, 500V, 531V 18.80 mm (0.74 in.) FH601V, 641V, 680V, 721V 19.90 mm (0.783 in.) • Measure the crankpin width [A] with a dial caliper.
  • Page 107: Crankshaft Runout

    If the crankpin diameter is less than the service limit, replace the crankshaft with a new one. Crankpin Outside Diameter Model Service Limit FH451V, 500V, 531V 34.94 mm (1.3756 in.) FH601V, 641V, 680V, 721V 37.94 mm (1.494 in.) Crankshaft Runout •...
  • Page 108: Crankpin Resizing

    If any cracks, no matter how small, are found, the crankshaft must be rejected. • The final finishing dimensions should be shown in the table. Finishing Dimensional Specifications [FH451V, FH500V, FH531V] 34.470 34.457 mm (1.357 1.356 in.) R 2.0 2.4 mm 39.50 mm MAX (1.555 in.
  • Page 109 ELECTRICAL SYSTEM 7-1 Electrical System Table of Contents Exploded View..................................7-2 Specifications ..................................7-6 Wiring Diagram [FH451V, FH500V, FH531V] ........................7-7 Wiring Diagram [FH601V, FH641V, FH680V, FH721V] ....................7-10 Precautions..................................7-11 Charging, Ignition System..............................7-12 Flywheel, Stator Coil Removal..........................7-12 Flywheel, Stator Coil Installation..........................7-13 Charging System Operational Inspection........................7-14...
  • Page 110: Exploded View

    7-2 ELECTRICAL SYSTEM Exploded View...
  • Page 111: Electrical System

    ELECTRICAL SYSTEM 7-3 Exploded View [FH451V, FH500V, FH531V] T1: 3.9 N m (0.40 kg m, 35 in T2: 5.9 N m (0.60 kg m, 52 in T3: 7.8 N m (0.80 kg m, 69 in T5: 56 N m (5.7 kg...
  • Page 112 7-4 ELECTRICAL SYSTEM Exploded View [FH451V, FH500V, FH531V]...
  • Page 113 ELECTRICAL SYSTEM 7-5 Exploded View [FH451V, FH500V, FH531V] T2: 5.9 N m (0.60 kg m, 52 in T3: 7.8 N m (0.80 kg m, 69 in T4: 17 N m (1.7 kg m, 12 ft G: Apply grease.
  • Page 114: Specifications

    7-6 ELECTRICAL SYSTEM Specifications Item Standard Service Limit FH451V, 500V, 531V FH601V, 641V, 680V, 721V Charging System: Regulated output voltage 14.1 V DC 15 V DC Alternator stator coil resistance in the text – – – Unregulated stator output 28.4 V AC/3000 rpm...
  • Page 115: Wiring Diagram [fh451v, Fh500v, Fh531v]

    ELECTRICAL SYSTEM 7-7 Wiring Diagram [FH451V, FH500V, FH531V]...
  • Page 116 7-8 ELECTRICAL SYSTEM Wiring Diagram [FH451V, FH500V, FH531V]...
  • Page 117 ELECTRICAL SYSTEM 7-9 Wiring Diagram [FH451V, FH500V, FH531V]...
  • Page 118: Wiring Diagram [fh601v, Fh641v, Fh680v, Fh721v]

    7-10 ELECTRICAL SYSTEM Wiring Diagram [FH601V, FH641V, FH680V, FH721V]...
  • Page 119: Precautions

    ELECTRICAL SYSTEM 7-11 Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below. Do not reverse the battery lead connections. This will burn out the diodes in the electrical parts. Always check battery condition before condemning other parts of an electrical system.
  • Page 120: Charging, Ignition System

    7-12 ELECTRICAL SYSTEM Charging, Ignition System Flywheel, Stator Coil Removal • Remove: Recoil Starter (see Recoil Starter Removal) Nuts [A] and Guard [B] Bolts [C] and Screen [D] Spacer [E] • Loosen the fan housing bolts [A] and remove the fan housing [B]. •...
  • Page 121: Flywheel, Stator Coil Installation

    ELECTRICAL SYSTEM 7-13 Charging, Ignition System • Remove: Woodruff Key [A] Stator Coil Lead Connector [B] Stator Coil Screw [C] Stator Coil [D] Flywheel, Stator Coil Installation • Install the stator coil and tighten the screws. Torque - Stator Coil Screws: 3.4 N m (0.35 kg m, 30 in •...
  • Page 122: Charging System Operational Inspection

    7-14 ELECTRICAL SYSTEM Charging, Ignition System • Install the fan housing and tight the bolts. Torque - Fan housing Bolts: 5.9 N m (0.6 kg m, 52 in • Install: Recoil Starter (see Recoil Starter Installation) • Install: Spacer [A] Screen [B] Position three sets [C] of screen notches around the fan blades.
  • Page 123: Stator Coil Resistance

    ELECTRICAL SYSTEM 7-15 Charging, Ignition System Stator Coil Resistance • Disconnect the connector [A]. • Measure the stator coil resistance. (Electric Starter Model) Connect an ohmmeter between stator pins [B]. Stator Coil Resistance (Electric Starter Model) 0.01 to 0.1 (Recoil Starter Model with Electric Clutch) Connect an ohmmeter between stator pin and engine-body.
  • Page 124: Regulator Resistance

    7-16 ELECTRICAL SYSTEM Charging, Ignition System Regulator Resistance • Set the KAWASAKI Hand Tester selector switch to the R position. • Connect the test leads to the points shown on the chart and read the resistance. There are two(2) types of Regulator on FH engines as follows: (with out Charging Monitor Type …3 Blades)
  • Page 125 ELECTRICAL SYSTEM 7-17 Charging, Ignition System This engine ignition is controlled by a solid state ignition assembly and requires no periodic maintenance except for the spark plugs. The system consists of the following: Inductive Ignition Assemblies Permanent Magnet Flywheel Spark Plugs Stop Switch Ignition Theory of Operation Mounted to the periphery of a flywheel are a pair of magnetic poles (south leading in clockwise rotation), generated by...
  • Page 126: Ignition Coil Removal

    7-18 ELECTRICAL SYSTEM Charging, Ignition System Ignition Coil Removal • Remove: Fan Housing (see Flywheel, Stator Coil Removal) Spark Plug Cap [A] Stop Switch Lead Connector [B] Bolts [C] Ignition Coil [D] Ignition Coil Installation • Install ignition coil on crankcase so that the stop switch lead connector [B] face the screen, and tighten bolt (1) first, then tighten bolt (2).
  • Page 127: Ignition Coil Inspection

    Ignition Coil Winding Resistance CAUTION Use only Tester 57001–1394 with new battery at room tempera- ture for this test. A tester other than the Kawasaki Hand Tester should show different readings. If a megger or a meter with a large-capacity battery is used, the ignition coil will be damaged.
  • Page 128: Starter System

    7-20 ELECTRICAL SYSTEM Starter System Starter Motor Removal • Remove the mounting bolts [A] and pull the starter motor [B] from the engine. Starter Motor Installation • Clean the starter motor and engine mounting flanges to ensure good electrical contact and tighten the mounting bolts. Torque - Starter Motor Mounting Bolts: 15 N m (1.5 kg...
  • Page 129: Starter Motor Disassembly

    ELECTRICAL SYSTEM 7-21 Starter System Starter Motor Assembly • Assembly is the reverse of disassembly. • Apply a small amount of grease [A] to the armature shaft. • Do not reuse the snap ring [B]. Replace it with a new one. •...
  • Page 130 7-22 ELECTRICAL SYSTEM Starter System • Measure the depth of the grooves between the commutator segments. If the grooves are shallower than the specified limit, replace the armature with a new one. If the grooves are only dirty, clean them carefully. Commutator Groove Depth Limit Less than 0.9 mm (0.035 in.) [A] Bad...
  • Page 131: Yoke Assembly Inspection

    ELECTRICAL SYSTEM 7-23 Starter System • Test the armature winding for shorts. Place the armature on a growler [A]. Hold a thin metal strip (e.g., hack saw blade) on top of the armature. Turn on the growler and rotate the armature one complete turn. If the metal strip vibrates, the windings are internally shorted to each other and the starter motor must be replaced.
  • Page 132: Recoil Starter Removal

    7-24 ELECTRICAL SYSTEM Starter System Recoil Starter Removal • Remove: Recoil Starter Mounting Nuts [A] Recoil Starter [B] Recoil Starter Installation • Install the recoil starter and tighten the mounting nuts. Torque - Recoil Starter Mounting Nuts: 5.9 N m (0.6 kg m, 52 in Recoil Starter Disassembly •...
  • Page 133: Recoil Starter Assembly

    ELECTRICAL SYSTEM 7-25 Starter System When removing the reel [A], be careful that the recoil spring [B] under the reel does not fly loose and cause injury. The spring is under great pressure. NOTE There should be no spring tension on the reel when removing it. If tension is felt, push the reel back into place and gently “wiggle”...
  • Page 134 7-26 ELECTRICAL SYSTEM Starter System • Lightly grease the shaft [A]. • Put the reel into the case, with the round peg [B] aligned with the spring inner tongue [C]. • Turn the reel clockwise until you feel the hang hook on the catch. •...
  • Page 135 TROUBLESHOOTING 8-1 Troubleshooting Table of Contents Engine Troubleshooting Guide ............................8-2 Starter Motor Troubleshooting Guide..........................8-6...
  • Page 136: Troubleshooting

    8-2 TROUBLESHOOTING Engine Troubleshooting Guide If the engine malfunctions, check if the way the engine is used is correct. If engine malfunctions even if engine is used correctly, systematically carry out troubleshooting starting with simple points. This chart describes typical troubleshooting procedures. Do not unnecessarily disassemble carburetor, magneto or engine unless it has been found to be the cause of malfunctioning.
  • Page 137 TROUBLESHOOTING 8-3 Engine Troubleshooting Guide...
  • Page 138 8-4 TROUBLESHOOTING Engine Troubleshooting Guide...
  • Page 139 TROUBLESHOOTING 8-5 Engine Troubleshooting Guide...
  • Page 140 8-6 TROUBLESHOOTING Starter Motor Troubleshooting Guide 1. Disconnect spark plug caps from the spark plugs. 2. Turn engine switch to “START” position and check condition. Engine may be cranked in this test. Do not touch any rotating parts of engine and equipment during test. CAUTION If starter does not stop by engine switch “OFF”, disconnect negative (−) lead from battery as soon as possible.

This manual is also suitable for:

Fh500vFh531vFh680vFh721vFh601vFh641v

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