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Kawasaki FR541V Service Manual

4-stroke air-cooled v-twin gasoline engine.
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FR541V, FR600V
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 FR541V

  • Page 1 FR541V, FR600V 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 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 Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan.
  • 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

    • the vehicle. 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)
  • Page 15: Model Identification

    GENERAL INFORMATION 1-7 Model Identification FR Models 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 16: General Specifications

    1-8 GENERAL INFORMATION General Specifications FS481V, FS541V, FS600V, FX481V, FX541V, FX600V, Item FR541V, FR600V 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 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 0.60 52 in·lb Rocker Cover Bolts...
  • Page 21 PERIODIC MAINTENANCE 2-5 Torque and Locking Agent The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.
  • Page 22: Specifications

    2-6 PERIODIC MAINTENANCE 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: FS Models Dual stage filtration system...
  • Page 23: Special Tools

    PERIODIC MAINTENANCE 2-7 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 24: Periodic Maintenance Procedures

    2-8 PERIODIC MAINTENANCE 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 25: Fuel System Cleanliness Inspection

    PERIODIC MAINTENANCE 2-9 Periodic Maintenance Procedures WARNING Moving parts can cause severe injury. 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 26: Element Cleaning And Inspection

    2-10 PERIODIC MAINTENANCE 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 27: Engine Top End

    PERIODIC MAINTENANCE 2-11 Periodic Maintenance Procedures Engine Top End Cylinder Head Cleaning • Scrape the carbon deposits from the cylinder head and the exhaust port with a suitable tool [A]. ○ To avoid gouging, use scrapers that are made of a mate- rial that will not cause damage.
  • Page 28: Valve Clearance Adjustment

    2-12 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) 0.10 ∼...
  • Page 29: Valve Seat Repair

    PERIODIC MAINTENANCE 2-13 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) 0.8 ∼...
  • Page 30 2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Marks Stamped on the Cutter The marks stamped on the back of the cutter represent the following. 32° Cutter angle [A] 37.5 Cutter diameter [B] KS8B Manufactured lot number Operating Procedures • Clean the seat area carefully. •...
  • Page 31 PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • Use a 32° seat cutter [A] to narrow the seat width to the standard width. ○ Turn the seat cutter one turn at a time while pressing down very lightly. Check the seat width after each turn. NOTICE The 32°...
  • Page 32: Lubrication System

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Lubrication System Engine 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 tube [C] without screwing it in, then check the oil level.
  • Page 33: Oil Filter Replacement

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Check the O-ring [A] on the oil filler cap for damage. Re- place the oil filler cap assembly if O-ring is damaged. When checking the oil level, do not turn oil filler cap on threads.
  • Page 35 FUEL SYSTEM 3-1 Fuel System Table of Contents Exploded View........................Specifications ......................... 3-10 Governor Link Mechanism...................... 3-12 Control Panel Assembly Removal ..................3-12 Control Panel Assembly Installation ................. 3-12 Governor Arm Removal ....................3-13 Governor Arm Installation ....................3-13 Governor Assembly Removal ................... 3-14 Governor Assembly Installation ..................
  • Page 36: Exploded View

    3-2 FUEL SYSTEM Exploded View FX Models...
  • Page 37 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 38 3-4 FUEL SYSTEM Exploded View FS Models...
  • Page 39 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 40 3-6 FUEL SYSTEM Exploded View FR Models...
  • Page 41 FUEL SYSTEM 3-7 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 Intake Manifold Bolts 0.90 78 in·lb Main Jet 0.17 15 in·lb Solenoid Valve 0.46 40 in·lb...
  • Page 42 3-8 FUEL SYSTEM Exploded View...
  • Page 43 FUEL SYSTEM 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Control Panel Mounting Bolt (FX and FR 0.60 52 in·lb Models) Governor Arm Clamp Nut 87 in·lb Governor Shaft Plate Screws 0.20 18 in·lb 4. FR Models 5. FS and FR Models EO: Apply engine oil.
  • Page 44: 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 FR541V Walbro/LMF-41 FR600V Walbro/LMF-24 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 45 FUEL SYSTEM 3-11 Specifications Item Standard US, Canada Using a minimum of 87 octane by antiknock index is recommended. Antiknock Index: (RON + MON)/2 RON = Research Octane Number MON = Motor Octane Number Using a minimum of 91 octane by RON is Other Countries recommended.
  • Page 46: Governor Link Mechanism

    3-12 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 47: Governor Arm Removal

    FUEL SYSTEM 3-13 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 48: Governor Assembly Removal

    3-14 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 49: Governor Shaft Installation

    FUEL SYSTEM 3-15 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 50: Carburetor

    3-16 FUEL SYSTEM Carburetor Fuel and Air Flow 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 51 FUEL SYSTEM 3-17 Carburetor 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 52: Fuel Shut Off Solenoid Valve

    3-18 FUEL SYSTEM Carburetor Fuel Shut Off Solenoid Valve 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 53: Fuel System Cleanliness Inspection

    FUEL SYSTEM 3-19 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: 1.7 N·m (0.17 kgf·m, 15 in·lb) • Replace the float chamber gasket with a new one. •...
  • Page 54: Intake Pipe Removal

    3-20 FUEL SYSTEM Carburetor Intake Pipe Removal 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] Recoil Starter Model •...
  • Page 55: Carburetor Removal

    FUEL SYSTEM 3-21 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 56: Carburetor Installation

    3-22 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 57: Carburetor Disassembly/assembly

    FUEL SYSTEM 3-23 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 and throt- tle valves for assembling them.
  • Page 58: Carburetor Cleaning

    3-24 FUEL SYSTEM Carburetor Carburetor Cleaning WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the carburetor in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this in- cludes any appliance with a pilot light.
  • Page 59: Carburetor Inspection

    FUEL SYSTEM 3-25 Carburetor Carburetor Inspection 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: Fuel Shut Off Solenoid Valve Test

    3-26 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 61: Intake Manifold

    FUEL SYSTEM 3-27 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. FS and FX Models [C] FR Models [D] Intake Manifold Installation •...
  • Page 62: Intake Manifold Inspection

    3-28 FUEL SYSTEM Intake Manifold • Tighten the intake manifold mounting bolts following the tightening sequence. Torque - Intake Manifold Mounting Bolts (FS and FX Mod- els): 5.9 N·m (0.60 kgf·m, 52 in·lb) Intake Manifold Mounting Bolts (FR Models): 8.8 N·m (0.90 kgf·m, 78 in·lb) •...
  • Page 63: Fuel Pump, Fuel Filter

    FUEL SYSTEM 3-29 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 64: Fuel Filter Removal/installation

    3-30 FUEL SYSTEM 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 65: Air Cleaner

    FUEL SYSTEM 3-31 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 66: Element Installation

    3-32 FUEL SYSTEM Air Cleaner FR Models • Open the air cleaner cover [A]. • Loosen the clamp [B]. • Remove the intake hose [C] together with the element assembly [D]. • Loosen the clamp [A]. • Remove the intake hose [B]. Element Installation FX Models •...
  • Page 67 FUEL SYSTEM 3-33 Air Cleaner FS Models • Install the form element [A] to the paper element [B]. • Install the intake hose [A], and tighten the clamp [B]. ○ Check that the element [C] is horizontally installed. • Install the intake hose [A], and tighten the clamp [B]. •...
  • Page 68: Element Cleaning And Inspection

    3-34 FUEL SYSTEM Air Cleaner • Install the intake hose [A], and tighten the clamp [B]. • Close the air cleaner cover [C]. 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 69: Air Cleaner Housing (cap And Body) Inspection

    FUEL SYSTEM 3-35 Air Cleaner • Set the air cleaner body [A] onto the lower bracket so that the air intake duct [B] is facing upward. • Install the intake hose [C], and tighten the clamp [D]. • Install the upper bracket [E]. •...
  • Page 71 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Cooling Fan ..........................4-10 Cooling Fan Removal ....................... 4-10 Cooling Fan Installation ....................4-10 Cooling Fan Inspection ..................... 4-10 Engine Shroud........................4-11 Engine Shroud Removal ....................4-11 Engine Shroud Installation ....................4-13...
  • Page 72: Exploded View

    4-2 COOLING SYSTEM Exploded View Electric Starter Model (FX Models)
  • Page 73 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cooling Fan Mounting Bolts 0.90 78 in·lb Cooling Fan Screen Screws 0.31 27 in·lb Engine Shroud Bolts 0.60 52 in·lb Fan Housing Bolts 0.60 52 in·lb Guard Mounting Bolts 0.60 52 in·lb...
  • Page 74 4-4 COOLING SYSTEM Exploded View Electric Starter Model (FS Models)
  • Page 75 COOLING SYSTEM 4-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cooling Fan Mounting Bolts 0.90 78 in·lb Cooling Fan Screen Screws 0.31 27 in·lb Engine Shroud Bolts 0.90 78 in·lb Fan Housing Bolts 0.90 78 in·lb 5. FS481/541/600V-AS00 ∼ DS00 Models...
  • Page 76 4-6 COOLING SYSTEM Exploded View Electric Starter Model (FR Models)
  • Page 77 COOLING SYSTEM 4-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cooling Fan Mounting Bolts 0.90 78 in·lb Cooling Fan Screen Screws 0.31 27 in·lb Engine Shroud Bolts 0.90 78 in·lb Fan Housing Bolts 0.90 78 in·lb 5. FR541/600V-AS00 ∼ CS00 Models...
  • Page 78 4-8 COOLING SYSTEM Exploded View Recoil Starter Model...
  • Page 79 COOLING SYSTEM 4-9 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 80: Cooling Fan

    4-10 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 81: Engine Shroud Removal

    COOLING SYSTEM 4-11 Engine Shroud Engine Shroud Removal 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) (FS and FX Models) Stator Coil Lead Connector (see Regulator Removal in the Electrical System chapter) Spark Plug Caps [A]...
  • Page 82 4-12 COOLING SYSTEM Engine Shroud FS and FR Models • Cut off the band [A]. 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]...
  • Page 83: Engine Shroud Installation

    COOLING SYSTEM 4-13 Engine Shroud Engine Shroud Installation 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 and FR Models) •...
  • Page 84 4-14 COOLING SYSTEM Engine Shroud FS and FR Models • 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 removed parts (see appropriate chapters). Recoil Starter Model •...
  • Page 85 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 ......................5-11 Push Rod Inspection......................
  • Page 86: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 87 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 88: 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 89 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 90: 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 91: 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 92: 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 93: Cylinder Head Assembly Installation

    ENGINE TOP END 5-9 Cylinder Head • Remove: Rocker Arm (see Valve Mechanism Removal/Installa- tion) Push Rod (see Push Rod Removal) Rocker Arm Bracket (see Valve Mechanism Removal/In- stallation) • Loosen the cylinder head bolts 1/4 turn in the sequence as shown in the figure.
  • Page 94: Push Rod Removal

    5-10 ENGINE TOP END Cylinder Head • Install the new gaskets and rocker covers. • Tighten the rocker cover bolts following the tightening se- quence as shown in the figure. Torque - Rocker Cover Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) FS and FX Models [A] FR Models [B] •...
  • Page 95: Push Rod Installation

    ENGINE TOP END 5-11 Cylinder Head Push Rod Installation • Set each piston at the T.D.C of the compression stroke. • Apply engine oil to the both ends and shaft of the push rod. • Install the push rods in their original positions of the tappet hollow [A].
  • Page 96 5-12 ENGINE TOP END Cylinder Head • Remove: Push Rod (see Push Rod Removal) Rocker Arm Bracket Bolts [A] Rocker Arm Brackets [B] • Remove the cylinder head assembly (see Cylinder Head Assembly Removal). • Support the valve head in the combustion chamber with a suitable block.
  • Page 97: Cylinder Head Cleaning

    ENGINE TOP END 5-13 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 98: Cylinder Head Inspection

    5-14 ENGINE TOP END 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 99: Valves

    ENGINE TOP END 5-15 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 100: Valve Guide Inside Diameter

    5-16 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 positions down the guide length. If the measurement is more than the service limit, replace the cylinder head with a new one.
  • Page 101: Cylinder, Piston

    ENGINE TOP END 5-17 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 102: Piston Installation

    5-18 ENGINE TOP END 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 103 ENGINE TOP END 5-19 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 104: Piston/cylinder Seizure

    5-20 ENGINE TOP END Cylinder, Piston • Insert the piston and connecting rod so that the arrow mark [A] on the top of the piston is facing the flywheel side. NOTICE 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.
  • Page 105: Piston Ring And Ring Groove Wear

    ENGINE TOP END 5-21 Cylinder, Piston • Clean the piston ring grooves [A] with a broken piston ring or other suitable tools. NOTICE Be careful not to widen the ring grooves. Damaged ring grooves will require piston replacement. Piston Ring and Ring Groove Wear •...
  • Page 106: Piston Ring End Gap

    5-22 ENGINE TOP END 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 107: Piston Diameter

    ENGINE TOP END 5-23 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 108 5-24 ENGINE TOP END 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 burrs and pieces of the base and head gasket.
  • Page 109 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 110: Exploded View

    6-2 LUBRICATION SYSTEM Exploded View...
  • Page 111 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 5. FX481/541/600V-AS00 and FS481/541/600V-AS00 ∼ BS00 Models EO: Apply engine oil.
  • Page 112: Engine Oil Flow Chart

    6-4 LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 113: 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 114: 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 115: Engine Oil And Oil Filter

    LUBRICATION SYSTEM 6-7 Engine Oil and Oil Filter NOTICE 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 116: 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 117: 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 118 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 119: 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 121 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 122: Exploded View

    7-2 CAMSHAFT/CRANKSHAFT Exploded View...
  • Page 123 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 124: 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 125: Special Tool

    CAMSHAFT/CRANKSHAFT 7-5 Special Tool Bearing Driver Set: Gasket-Liquid, TB1217H: 57001-1129 92104-7001...
  • Page 126: 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 127: 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 128: 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 129: Crankcase Assembly

    CAMSHAFT/CRANKSHAFT 7-9 Crankcase Crankcase Assembly • Remove the old gasket from the mating surfaces of the crankcase and cover. • Using compressed air, blow out the oil passage in the crankcase. • With a high flash-point solvent, clean off the mating sur- faces of the crankcase and the cover, and wipe them dry.
  • Page 130: Crankcase And Crankcase Cover Cleaning

    7-10 CAMSHAFT/CRANKSHAFT Crankcase Crankcase and Crankcase Cover Cleaning • Remove: Oil Pump and Relief Valve (see Oil Pump, Relief Valve Removal in the Lubrication System chapter) Camshaft and Tappets (see Camshaft, Tappet Removal) Crankshaft (see Crankshaft Removal) Breather Valve and Cover (see Breather Valve Removal) •...
  • Page 131: Breather

    CAMSHAFT/CRANKSHAFT 7-11 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 132 7-12 CAMSHAFT/CRANKSHAFT Breather Recoil Starter Model (FX Models)
  • Page 133 CAMSHAFT/CRANKSHAFT 7-13 Breather Electric Starter Model (FS and FR Models)
  • Page 134 7-14 CAMSHAFT/CRANKSHAFT Breather Recoil Starter Model (FS Models)
  • Page 135: Breather Valve Removal

    CAMSHAFT/CRANKSHAFT 7-15 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) Breather Valve Mounting Screw [B] Back Plate [C] Reed Valve [D]...
  • Page 136: Breather Valve Inspection

    7-16 CAMSHAFT/CRANKSHAFT 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 137: Camshaft, Tappet

    CAMSHAFT/CRANKSHAFT 7-17 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 138: Camshaft Assembly

    7-18 CAMSHAFT/CRANKSHAFT 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 139 CAMSHAFT/CRANKSHAFT 7-19 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 140: Crankshaft, Connecting Rod

    7-20 CAMSHAFT/CRANKSHAFT 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 141: Connecting Rod Bend/twist

    CAMSHAFT/CRANKSHAFT 7-21 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 142: Connecting Rod Big End Bearing/crankpin Wear

    7-22 CAMSHAFT/CRANKSHAFT 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 143: Crankshaft Main Journal/wear

    CAMSHAFT/CRANKSHAFT 7-23 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 145 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 ......................8-10 Starter Motor Disassembly....................8-11 Starter Motor Assembly ....................8-14 Starter Motor Brush Inspection ..................
  • Page 146: Exploded View

    8-2 STARTER SYSTEM Exploded View FS and FX, FR541/600V-DS00 Model...
  • Page 147 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 3.95 0.40 35 in·lb 3. FS481/541/600V-AS00 Models 4. FX481/541/600V-AS00 Models 5. FS481/541/600V-AS00 ∼ DS00 Models 6. FS481/541/600V-ES00 and FR541/600V-ES00 Models G: Apply grease.
  • Page 148 8-4 STARTER SYSTEM Exploded View FR541/600V-AS00 ∼ CS00 Models...
  • Page 149 STARTER SYSTEM 8-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Starter Motor Mounting Bolts 19.6 Starter Motor Through Bolts 5.88 0.60 52 in·lb Armature Shaft Nut 10.3 1.05 91 in·lb G: Apply grease. R: Replacement Parts...
  • Page 150 8-6 STARTER SYSTEM Exploded View Recoil Starter Model...
  • Page 151 STARTER SYSTEM 8-7 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 152: Specifications

    8-8 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.) FR Models 12.8 mm (0.50 in.) 6.4 mm (0.25 in.) Commutator Groove Depth: FX Models...
  • Page 153: Electric Starter System

    STARTER SYSTEM 8-9 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 154: Starter Motor Test

    8-10 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 155: Starter Motor Disassembly

    STARTER SYSTEM 8-11 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 156 8-12 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 157 STARTER SYSTEM 8-13 Electric Starter System • Remove: Snap Ring [A] Retainer [B] Spring [C] Pinion Gear [D] Rubber Damper [E] • Clockwise to remove the color [A]. • Remove the end cover [B]. • Remove the armature from the yoke. FS481/541/600V-ES00 and FR541/600V-DS00 Models •...
  • Page 158: Starter Motor Assembly

    8-14 STARTER SYSTEM Electric Starter System • Remove the yoke [A]. • While holding the armature [A], remove the armature shaft nut [B]. NOTE ○ Do not hold the armature in a vise. The armature may a damaged. • Remove: Stop Plug [C] Spring [D] Pinion Gear [E]...
  • Page 159 STARTER SYSTEM 8-15 Electric Starter System • Inspect the boots [A], grommet [B] and rubber insert [C] for visible damage. If it is damaged, replace the related parts. • Install the pinion clutch [A]. • Install the rear stopper [B] so that the hollow side face the outside.
  • Page 160 8-16 STARTER SYSTEM Electric Starter System • Install the brush holder [A]. • Install the brushes [B] to the brush holder. • Install the springs [A]. • Install the insulator [A]. • Install the end cover so that the slit [A] fit the groove [B] of the grommet.
  • Page 161 STARTER SYSTEM 8-17 Electric Starter System • Install the yoke so that the slit [A] fit the groove [B] of the brush plate assembly. FS481/541/600V-AS00 ∼ DS00 Models • Apply grease to the armature shaft. • Install the end cover so that the slit [A] fit the projection [B] of the yoke.
  • Page 162 8-18 STARTER SYSTEM Electric Starter System • Do not reuse the snap ring [A]. Replace it with a new one. • Install: Collar [B] Spacer [C] Pinion Gear [D] Spacer [E] Spring [F] Washer [G] Snap Ring • Make sure that grease does not attach to the contact por- tion between the collar and the rubber damper.
  • Page 163: Starter Motor Brush Inspection

    STARTER SYSTEM 8-19 Electric Starter System • Using the suitable tool, hold the brushes. • Install the brush plate assembly so that the slit [A] fit the projection [B] of the yoke. • Tighten: Torque - Start Motor Through Bolts: 5.88 N·m (0.60 kgf·m, 52 in·lb) Starter Motor Brush Inspection •...
  • Page 164: Armature Inspection

    8-20 STARTER SYSTEM Electric Starter System Armature Inspection • Inspect the surface of the commutator [A]. If it is scratched or dirty, polish it with a piece of very fine emery cloth [B], and clean out the grooves. FS and FX Models [C] FR Models [D] FS and FX Models •...
  • Page 165 STARTER SYSTEM 8-21 Electric Starter System FS and FX Models • Measure the outside diameter [A] of the commutator [B] at several points. If the diameter is less than the service limit, replace the armature with a new one. Commutator Outside Diameter Standard: FX Models 28.0 mm (1.10 in.)
  • Page 166 8-22 STARTER SYSTEM Electric Starter System • Set the multimeter selector switch to the R × 1 kΩ position and measure the resistance between the commutator and the armature shaft. If the resistance is less than infinite, the armature is shorted.
  • Page 167: Yoke Assembly Inspection

    STARTER SYSTEM 8-23 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 168: Pinion Clutch Inspection

    8-24 STARTER SYSTEM 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 169: Recoil Starter Removal

    STARTER SYSTEM 8-25 Electric Starter System Recoil Starter Removal • Remove: Recoil Starter Mounting Bolts [A] Recoil Starter [B] FX Models [C] FS Models [D] 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)
  • Page 170: Recoil Starter Assembly

    8-26 STARTER SYSTEM Electric Starter System • While carefully holding the reel [A] and case [B], remove the clip. • Unwind the spring tension slowly. NOTE ○ Do not wedge the rope between the reel and case. • Loosen the screw [A]. •...
  • Page 171 STARTER SYSTEM 8-27 Electric Starter System • Wind the rope [A] clockwise [B] on the reel [C]. • Lightly grease the shaft [A]. • Install the reel [B] into the case [C]. ○ Hook the spring hook [D] to the case tab [E]. •...
  • Page 173 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 174: Exploded View

    9-2 ELECTRICAL SYSTEM Exploded View Electric Starter Model...
  • Page 175 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 and FR Models 6. FR Models 7. FR541/600V-AS00 ∼ CS00 Models G: Apply dielectric grease.
  • Page 176 9-4 ELECTRICAL SYSTEM Exploded View Recoil Starter Model...
  • Page 177 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 178: 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 Recoil Starter Model –...
  • Page 179: Special Tool

    ELECTRICAL SYSTEM 9-7 Special Tool Hand Tester: 57001-1394...
  • Page 180: Wiring Diagram

    9-8 ELECTRICAL SYSTEM Wiring Diagram Electric Starter Model (FX Models)
  • Page 181 ELECTRICAL SYSTEM 9-9 Wiring Diagram Electric Starter Model (FS and FR Models)
  • Page 182 9-10 ELECTRICAL SYSTEM Wiring Diagram Recoil Starter Model...
  • Page 183: 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 184: Charging System

    9-12 ELECTRICAL SYSTEM Charging System Flywheel and Stator Coil Removal Electric Starter Model (FX Models) • 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 185 ELECTRICAL SYSTEM 9-13 Charging System • Remove: Bolts [A] Fan Housing [B] Electric Starter Model (FX and FS481/541/600V-AS00 ∼ DS00, FR541/600V-AS00 ∼ CS00 Models) • Remove: Ignition Coils [A] (see Ignition Coil Removal) Bolts [B] Cooling Fan [C] • Hold the flywheel with a suitable tool [A], remove the fly- wheel bolt [B] and washer.
  • Page 186 9-14 ELECTRICAL SYSTEM Charging System Electric Starter Model (FX Models) • Free the stator coil lead [A], stop switch lead [B] and so- lenoid valve connector lead [C] from the engine shroud clamp [D]. Electric Starter Model (FS and FR Models) •...
  • Page 187 ELECTRICAL SYSTEM 9-15 Charging System • Remove the fan housing stud bolts [A]. Recoil Starter Model (FS and FX Models) • Remove the ignition coils (see Ignition Coil Removal). • Hold the flywheel with a suitable tool [A], remove the fly- wheel bolt and washer.
  • Page 188: Flywheel And Stator Coil Installation

    9-16 ELECTRICAL SYSTEM Charging System Recoil Starter Model (FS Models) • Cut off the band [A]. Recoil Starter Model (FS and FX Models) • Remove: Woodruff Key [A] Stator Coil Screws [B] Stator Coil [C] Flywheel and Stator Coil Installation Electric Starter Model (FS and FX, FR Models) •...
  • Page 189 ELECTRICAL SYSTEM 9-17 Charging System • Install the cooling fan [A]. • Tighten: Torque - Cooling Fan Mounting Bolts [B]: 8.8 N·m (0.90 kgf·m, 78 in·lb) Electric Starter Model (FS481/541/600V-ES00 and FR541/600V-DS00 Models) • Install the cooling fan [A] and plate [B]. •...
  • Page 190 9-18 ELECTRICAL SYSTEM Charging System Electric Starter Model (FX Models) • Install the guard [A] and tighten the bolts [B]. Torque - Guard Mounting Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) Electric Starter Model (FS and FR541/600V-DS00 Mod- els) • Install the guard [A] and screw rivets [B].
  • Page 191 ELECTRICAL SYSTEM 9-19 Charging System • Install the pulley plate [A] so that the notch [B] inserts into the slot [C] in the flywheel. • Install the pulley [A] with the screen [B] so that the tabs [C] of the plate [D] fit into the holes [E]. •...
  • Page 192: Charging System Operational Inspection

    9-20 ELECTRICAL SYSTEM Charging System Recoil Starter Model (FS and FX Models) • Install the crankcase stud bolts and tighten them [FS Mod- els (Recoil Starter Model only)]. • Install the fan housing and tighten the bolts. Torque - Fan Housing Bolts (FX Models): 5.9 N·m (0.60 kgf·m, 52 in·lb) Fan Housing Bolts (FS Models): 8.8 N·m (0.90 kgf·m, 78 in·lb)
  • Page 193: Unregulated Stator Output

    ELECTRICAL SYSTEM 9-21 Charging System • Measure the stator coil resistance. Recoil Starter Model ○ Connect a hand tester between the stator coil lead con- nector [A] and engine body. Special Tool - Head Tester: 57001-1394 Stator Coil Resistance 4.4 ∼ 15 Ω If the measured value is not within the specification, re- place the stator coil with a new one.
  • Page 194: Regulator Installation

    Electric Starter Model • Remove the regulator (see Regulator Removal). • Set the KAWASAKI Hand Tester selector switch to the R × 100 Ω position. Special Tool - Hand Tester: 57001-1394 • Connect the test leads to the points shown on the chart and read the resistance.
  • Page 195: 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 196: 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] Electric Starter Model/Recoil Starter Model (FX Models) Recoil Starter Model (FS Models) [H]...
  • Page 197: 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 198: Ignition Coil Inspection

    NOTICE 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 199 TROUBLESHOOTING 10-1 Troubleshooting Table of Contents Engine Troubleshooting Guide ....................10-2 Starter Motor Troubleshooting Guide ..................10-6...
  • Page 200: 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 201 TROUBLESHOOTING 10-3 Engine Troubleshooting Guide...
  • Page 202 10-4 TROUBLESHOOTING Engine Troubleshooting Guide...
  • Page 203 TROUBLESHOOTING 10-5 Engine Troubleshooting Guide...
  • Page 204 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 205 Part No.99924-2094-04 Printed in Japan...

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