!! FH601D FH641D FH680D FH721D KAWASAKI SERVICE REPAIR MANUAL 99924206002

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FH601D FH641D

FH680D FH721D

4–stroke air-cooled v-twin gasoline engine

Service Manual

form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of

Quality Assurance Department/Consumer Products & Machinery Company/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.

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LIST OF ABBREVIATIONS

A ampere(s) lb pound(s)

ABDC after bottom dead center m meter(s)

AC alternating current min minute(s)

ATDC after top dead center N newton(s)

BBDC before bottom dead center Pa pascal(s)

BDC bottom dead center PS horsepower

BTDC before top dead center psi pound(s) per square inch

Cdegree(s) Celsius r revolution

DC direct current rpm revolution(s) per minute

F farad(s) TDC top dead center

F degree(s) Fahrenheit TIR total indicator reading

ft foot, feet V volt(s)

g gram(s) W watt(s)

h hour(s) ohm(s)

L liter(s)

Read OWNER’S MANUAL before operating.

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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.

1. Crankcase Emission Control System

A sealed-type crankcase emission control system is used to eliminate blow-by gasses. The blow-by

gasses are led to a breather chamber through the crankcase and from there to the air cleaner.

Oil is separated from the gasses while passing through the inside of the breather chamber from the

crankcase, and then returned to the bottom of crankcase.

2. Exhaust Emission Control System

The exhaust emission control system applied to this engine consists of a carburetor and an ignition

system having optimum ignition timing characteristics.

The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel

economy with a suitable air cleaner and exhaust system.

TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED

Federal law and California State law prohibits the following acts or the causing thereof: (1) the removal or rendering

inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of

design incorporated into any new engine for the purpose of emission control prior to its sale or delivery to the ultimate

purchaser or while it is in use, or (2) the use of the engine after such device or element of design has been removed or

rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

Do not tamper with the original emission related part:

•Carburetor and internal parts

•Spark plugs

•Magneto or electronic ignition system

•Fuel ﬁlter element

•Air cleaner elements

•Crankcase

•Cylinder heads

•Breather chamber and internal parts

•Intake pipe and tube

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Foreword

This manual is designed primarily for use by trained

mechanics in a properly equipped shop. However, it

contains enough detail and basic information to make

it useful to the owner who desires to perform his own

basic maintenance and repair work. A basic knowledge

of mechanics, the proper use of tools, and workshop

procedures must be understood in order to carry out

maintenance and repair satisfactorily. Whenever the

owner has insufﬁcient experience or doubts as to his

ability to do the work, all adjustments, maintenance, and

repair should be carried out only by qualiﬁed mechanics.

In order to perform the work efﬁciently and to avoid

costly mistakes, read the text, thoroughly familiarize

yourself with the procedures before starting work, and

then do the work carefully in a clean area. Whenever

special tools or equipment are speciﬁed, do not use

makeshift tools or equipment. Precision measurements

can only be made if the proper instruments are used,

and the use of substitute tools may adversely affect safe

operation.

To get the longest life out of your engine:

•Follow the Periodic Maintenance Chart in the Service

Manual.

•Be alert for problems and non-scheduled maintenance.

•Use proper tools and genuine Kawasaki engine parts.

Genuine parts provided as spare parts are listed in the

Parts Catalog.

•Follow the procedures in this manual carefully. Don’t

take shortcuts.

•Remember to keep complete records of maintenance

and repair with dates and any new parts installed.

How to Use This Manual

In preparing this manual, we divided the product into

its major systems. These systems became the manual’s

chapters. All information for a particular system from

adjustment through disassembly and inspection is located

in a single chapter.

The Quick Reference Guide shows you all of the

product’s system and assists in locating their chapters.

Each chapter in turn has its own comprehensive Table of

Contents.

The Periodic Maintenance Chart is located in the

General Information chapter. The chart gives a time

schedule for required maintenance operations.

If you want spark plug information, for example, go to

the Periodic Maintenance Chart ﬁrst. The chart tells you

how frequently to clean and gap the plug. Next, use the

Quick Reference Guide to locate the Electrical System

chapter. Then, use the Table of Contents on the ﬁrst page

of the chapter to ﬁnd the Spark Plug section.

Whenever you see these WARNING and CAUTION

symbols, heed their instructions! Always follow safe

operating and maintenance practices.

This warning symbol identiﬁes special instruc-

tions or procedures which, if not correctly fol-

lowed, could result in personal injury, or loss of

life.

CAUTION

This caution symbol identiﬁes special instruc-

tions or procedures which, if not strictly ob-

served, could result in damage to or destruction

of equipment.

This manual contains four more symbols (in addition to

WARNING and CAUTION) which will help you distinguish

different types of information.

NOTE

This note symbol indicates points of particular in-

terest for more efﬁcient and convenient operation.

•Indicates a procedural step or work to be done.

Indicates a procedural sub-step or how to do the work

of the procedural step it follows. It also precedes the

text of a WARNING, CAUTION, or NOTE.

Indicates a conditional step or what action to take based

on the results of the test or inspection in the procedural

step or sub-step it follows.

In most chapters an exploded view illustration of the

system components follows the Table of Contents. In

these illustrations you will ﬁnd the instructions indicating

which parts require speciﬁed tightening torque, oil, grease

or a locking agent during assembly.

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GENERAL INFORMATION 1-1

General Information

Table of Contents

Before Servicing................................................................................................................................................................1-2

Model Identiﬁcation...........................................................................................................................................................1-4

General Speciﬁcations......................................................................................................................................................1-5

Periodic Maintenance Chart..............................................................................................................................................1-6

Torque and Locking Agent................................................................................................................................................1-7

Special Tools.....................................................................................................................................................................1-9

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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. Any dirt entering the engine, carburetor, or other parts, will

work as an abrasive and shorten the life of engine. For the same reason, before installing a new part, clean off any

dust or metal ﬁlings.

(2) Battery Ground

Remove the ground (—) lead from the battery before performing any disassembly operations on the equipment.

This prevents:

(a) the possibility of accidentally turning the engine over while partially disassembled.

(b) sparks at electrical connections which will occur when they are disconnected.

(3) Tightening Sequence

Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to

a snug ﬁt. Then tighten them evenly, in a staggered sequence. This is to avoid distortion of the part and/or causing

gas or oil leakage. Conversely when loosening the bolts, nuts, or screws, ﬁrst loosen all of them by about a quarter

of a turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts,

nuts, or screws must be tightened in the order and method indicated.

(4) Torque

When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to

serious damage. Use a good quality, reliable torque wrench.

(5) Force

Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially

difﬁcult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap

lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removal of screws

held by a locking agent) in order to avoid damaging the heads.

(6) Edges

Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves

or a piece of thick cloth when lifting the engine or turning it over.

(7) High-Flash Point Solvent

A high-ﬂash point solvent is recommended to reduce ﬁre danger. A commercial solvent commonly available in North

America is Standard solvent (generic name). Always follow manufacturer and container directions regarding the use

of any solvent.

(8) Gasket, O-Ring

Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be

free of foreign matter and perfectly smooth to avoid oil or compression leaks.

(9) Liquid Gasket, Non-Permanent Locking Agent

Follow manufacturer’s directions for cleaning and preparing surfaces where these compounds will be used. Apply

sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a non-

permanent locking agent commonly available in North America is Loctite Lock’n Seal (Blue).

(10) Press

A part installed using a press or driver, such as a journal, should ﬁrst be coated with oil on its outer or inner

circumference so that it will go into place smoothly.

(11) Ball Bearing

When installing a ball bearing, the bearing race which is affected by friction should be pushed by a suitable driver.

This prevents severe stress on the balls and races, and prevents races and balls from being dented. Press a ball

bearing until it stops at the stop in the hole or on the shaft.

(12) Oil Seal and Grease Seal

Replace any oil or grease seals that were removed with new ones, as removal generally damages 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.

(13) Seal Guide

A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips. Before

a shaft passes through a seal, apply a little oil, preferably high temperature grease on the lips to reduce rubber to

metal friction.

(14) Circlip, Retaining Ring

Replace any circlips and retaining rings that were removed with new ones, as removal weakens and deforms them.

When installing circlips and retaining rings, take care to compress or expand them only enough to install them and

no more.

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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. During assembly, oil or grease (whichever is more suitable) should be applied to any

rubbing surface which has lost its lubricative ﬁlm. Old grease and dirty oil should be cleaned off. Deteriorated grease

has lost its lubricative quality and may contain abrasive foreign particles.

Don’t use just any oil or grease. Some oils and greases in particular should be used only in certain applications and

may be harmful if used in an application for which they are not intended. This manual makes reference to molybdenum

disulﬁde grease (MoS2) in the assembly of certain engine parts. Always check manufacturer recommendations before

using such special lubricants.

(17) Electrical Wires

All the electrical wires are either single-color or two-color and, with only a few exceptions, must be connected to

wires of the same color. On any of the two-color wires there is a greater amount of one color and a lesser amount of

a second color, so a two-color wire is identiﬁed by ﬁrst the primary color and then the secondary color. For example,

a yellow wire with thin red stripes is referred to as a "yellow/red" wire; it would be a "red/yellow" wire if the colors were

reversed to make red the main color.

(18) Replacement Parts

When there is a replacement instruction, replace these parts with new ones every time they are removed. There

replacement parts will be damaged or lose their original function once removed.

(19) Inspection

When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If

there is any doubt as to the condition of them, replace them with new ones.

Abrasion Crack Hardening Warp

Bent Dent Scratch Wear

Color change Deterioration Seizure

(20) Speciﬁcations

Speciﬁcation terms are deﬁned as follows:

"Standards" show dimensions or performances which brand-new parts or systems have.

"Service Limits" indicate the usable limits. If the measurement shows excessive wear or deteriorated performance,

replace the damaged parts.

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1-4 GENERAL INFORMATION

Model Identiﬁcation

Cylinder Number Designation:

No.1 Cylinder is on the electric starter side.

No.2 Cylinder is on the oil ﬁleter side.

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GENERAL INFORMATION 1-5

General Speciﬁcations

Items FH601D, FH641D, FH680D, FH721D

Type of engine Forced air-cooled, horizontal shaft, OHV, 4-stroke gasoline engine.

Cylinder layout 90 V-Twin

Bore x Stroke 75.2 mm x 76 mm (2.96 in x 2.99 in)

Piston displacement 675 mL (41.19 cu. in)

Direction of rotation Counterclockwise facing the PTO shaft

Compression release Automatic compression release

Low idle speed 1550 rpm

Fast idle speed 3600 rpm

Ignition system Transistorized-ﬂy wheel magneto

RFI Per Canada and U.S.A. requirements

Starting system Electric starter

Charging system 12 V - 13 amps with regulator

Spark plug NGK BPR4ES

Carburetor Float type, ﬁxed main jet, two barrel

Fuel pump Diaphragm type pulse pump

Air cleaner Dual stage element, dry type

Governor Flyweight all speed governor

Lubrication system Pressure feed by positive displacement pump

Oil ﬁlter Cartridge type full ﬂow ﬁlter

Oil pressuer switch ON-OFF switch

Oil capacity 1.6 L (1.7 US qt)…(when engine is completely dry)

Cooling system Forced air cooling by fan

Dimensions (L x W x H ): without mufﬂer 442 mm x 430 mm x 491 mm (17.4 in x 16.9 in x 19.3 in)

Dry weight: without mufﬂer 44.5 kg (98.1 lb)

Speciﬁcations subject to change without notice.

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1-6 GENERAL INFORMATION

Periodic Maintenance Chart

To ensure satisfactory operation over an extended period of time, any engine requires normal maintenance regular

intervals. The Periodic Maintenance Chart below shows periodic inspection and maintenance items and suitable intervals.

The bullet mark (•) designates that the corresponding item should be performed at that interval.

Some adjustments require the use of special tools or other equipment. An electronic tachometer will facilitate setting

idle and running speeds.

OPERATION INTERVAL

Daily First

8hr.

Every

25 hr.

Every

50 hr.

Every

100 hr.

Every

200 hr.

Every

300 hr.

Check or clean air intake screen •

Check and add engine oil •

Check for fuel and oil leakage •

Check for loose or lost nut and screw •

Check battery electrolyte level •

Clean air cleaner foam element (1) •

Clean air cleaner paper element (1) •

Clean dust and dirt from cylinder and •

cylinder head ﬁns (1)

Tighten nut and screws •

Change engine oil • •

Clean and re-gap spark plugs •

Check and clean oil cooler ﬁns •

(FH721D engines).

Change Oil ﬁlter •

Change air cleaner paper element (1) •

♦Check and adjust vlave clearance •

♦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.

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GENERAL INFORMATION 1-7

Torque and Locking Agent

The following tables lists the tightening torque for the major fasteners, and the parts requiring use of a non-permanent

locking agent or liquid gasket.

Letters used in the "Remarks" column mean:

L:Apply a non-permanent locking agent to the threads.

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.

Fastener Torque Remarks

Nmkgf m ft lb

Fuel System:

Choke Valve Screw ♦0.95 ♦0.097 ♦8.4 in lb ♦=L

Throttle Valve Screws ♦0.95 ♦0.097 ♦8.4 in lb ♦=L

Plug, Main Jet 18 1.8 13

Drain Screw (Carburetor) 2.0 0.2 18 in lb

Fuel Shut Off Solenoid Valve (Carburetor) 19 1.9 14

Float Chamber Mounting Screw (Carburetor) 4.0 0.4 35 in lb

Governor Arm Clamp Nut 7.8 0.8 69 in lb

Governor Shaft Plate Screws 2.0 0.2 17 in lb

Carburetor and Intake Pipe Mounting Bolts and Nuts 5.9 0.6 52 in lb

Intake Manifold Mounting Bolts 5.9 0.6 52 in lb

Air Cleaner Body Mounting Bolts 5.9 0.6 52 in lb

Control Panel Mounting Bolts 5.9 0.6 52 in lb

Cooling System:

Screen Bolts 5.9 0.6 52 in lb

Engine-shroud Bolt (M8: on Cylinder Head) 6.9 0.7 61 in lb

Engine-shroud Bolts (M6) 5.9 0.6 52 in lb

Engine Top End:

Cylinder Head Bolts ♦28 ♦2.8 ♦21 ♦=S

Valve Clearance Lock Screws 6.9 0.7 61 in lb

Connecting Rod Big End Cap Bolts ♦9.8 ♦1.0 ♦87 in lb ♦=O

Rocker Arm Bolts 28 2.8 21

Rocker Cover Mounting Bolts 6.9 0.7 61 in lb

Mufﬂer Flange Nuts 15 1.5 11

Spark Plugs 22 2.2 16

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1-8 GENERAL INFORMATION

Torque and Locking Agent

Fastener Torque Remarks

N m kgf m ft lb

Lubrication System:

Engine Drain Plugs (Plastic) 6.9 0.7 61 in lb

Engine Drain Plug (Metal) 20 2.0 14.5

Engine Drain Plug Joint (Plastic) 17 1.7 12

Engine Drain Plug Joint (Metal) 39 4.0 29

Oil Pressure Switch ♦9.8 ♦1.0 ♦87 in lb ♦=SS

Oil Pump Cover Plate Mounting Bolts 5.9 0.6 52 in lb

Oil Filter (see Page 5-6) in the text

Camshaft/Crankshaft:

Crankcase Cover Bolts ♦25 ♦2.6 ♦19 ♦=S

Breather Chamber Cover Bolts 5.9 0.6 52 in lb

Electrical System:

Stator Coil Screws 3.4 0.35 30 in lb

Flywheel Bolt 56 5.7 41

Fan Housing Bolts (M8) 6.9 0.70 61 in lb

Fan Housing Bolts (M6) 5.9 0.6 52 in lb

Screen Bolts 5.9 0.6 52 in lb

Regulator Screws 3.4 0.35 30 in lb

Ignition Coil Bolts 5.9 0.6 52 in lb

Starter Motor Mounting Bolts 15 1.5 11

Spark Plugs 22 2.2 16

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.

Basic Torque for General Fasteners

Threads dia Torque

(mm) N m kg m ft lb

4 2.0 0.2 17 in lb

5 3.4 0.35 30 in lb

6 5.9 0.6 52 in lb

8 15 1.5 11

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GENERAL INFORMATION 1-9

Special Tools

Compression Gauge: 57001–221

Piston Ring Pliers: 57001–115

Piston Ring Compression Grip: 57001–1095

Piston Ring Compression Belt, Ø67 -Ø79: 57001–1097

Valve Seat Cutter Holder Bar: 57001–1128

Valve Seat Cutter Holder Ø6: 57001–1360

Valve Seat Cutter, 45 –35.0 : 57001–1116

Valve Seat Cutter, 32 – 33.0 : 57001–1199

Compression Gauge Adapter M14 x 1.25: 57001–1159

Valve Seat Cutter, 32 – 30 : 57001–1120

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1-10 GENERAL INFORMATION

Special Tools

Oil Filter Wrench : 57001–1249

Hand Tester: 57001–1394

Kawasaki Bond (Silicone Sealant) : 56019–120

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FUEL SYSTEM 2-1

Fuel System

Table of Contents

Exploded View...................................................................................................................................................................2-2

Speciﬁcations....................................................................................................................................................................2-4

Governor Link Mechanism................................................................................................................................................2-5

Control Panel Assembly Removal..............................................................................................................................2-5

Control Panel Assembly Installation...........................................................................................................................2-5

Governor Arm Removal..............................................................................................................................................2-5

Governor Arm Installation..........................................................................................................................................2-6

Governor Assembly Removal.....................................................................................................................................2-6

Governor Assembly Installation..................................................................................................................................2-6

Governor Assembly Inspection..................................................................................................................................2-7

Governor Shaft Removal............................................................................................................................................2-7

Governor Shaft Installation.........................................................................................................................................2-7

Carburetor.........................................................................................................................................................................2-8

Fuel and Air Flow.......................................................................................................................................................2-8

Fuel Shut Off Solenoid Valve (Electric Starter Model).............................................................................................. 2-9

Low Idle Speed Adjustment.......................................................................................................................................2-9

High Idle Speed Adjustment .................................................................................................................................... 2-10

High Altitude Operation............................................................................................................................................2-11

Main Jet Replacement.............................................................................................................................................2-11

Fuel System Cleanliness Inspection........................................................................................................................2-11

Carburetor Removal.................................................................................................................................................2-11

Carburetor Installation..............................................................................................................................................2-12

Carburetor Disassembly/Assembly...........................................................................................................................2-13

Carburetor Cleaning.................................................................................................................................................2-14

Carburetor Inspection...............................................................................................................................................2-14

Fuel Shut-Off Solenoid Valve Test...........................................................................................................................2-15

Intake Manifold................................................................................................................................................................2-16

Intake Manifold Removal..........................................................................................................................................2-16

Intake Manifold Installation.......................................................................................................................................2-16

Intake Manifold Inspection........................................................................................................................................2-17

Fuel Pump, Fuel Filter.....................................................................................................................................................2-18

Fuel Pump Inspection.............................................................................................................................................. 2-18

Fuel Filter Inspection................................................................................................................................................2-18

Air Cleaner......................................................................................................................................................................2-19

Element Removal.....................................................................................................................................................2-19

Element Installation..................................................................................................................................................2-19

Element Cleaning and Inspection............................................................................................................................2-19

Cleaner Body Removal ............................................................................................................................................2-20

Cleaner Body Installation.........................................................................................................................................2-20

Housing (Cover and Body) Inspection.....................................................................................................................2-20

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2-2 FUEL SYSTEM

Exploded View

1. Pilot Screw

2. Pilot Air Jet

3. Main Air Jet

4. Main Jet

5. Pilot Jet

6. Solenoid Valve

T1: 0.95 N m (0.097 kgf m, 8.4 in lb)

T2: 0.98 N m (0.1 kgf m, 8.7 in lb)

T3: 2.0 N m (0.2 kgf m, 18 in lb)

T4: 3.4 N m (0.35 kgf m, 30 in lb)

T5: 5.9 N m (0.6 kgf m, 52 in lb)

T6: 19 N m (1.9 kgf m, 14 ft lb)

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FUEL SYSTEM 2-3

Exploded View

O: Apply engine oil.

T1: 2.0 N m (0.2 kgf m, 17 in lb)

T2: 5.9 N m (0.6 kgf m, 52 in lb)

T3: 7.8 N m (0.8 kgf m, 69 in lb)

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2-4 FUEL SYSTEM

Speciﬁcations

Item Standard

FH601D, FH641D FH680D, FH721D

Caburetors Speciﬁcations:

Make/ type Nikki 13Y244 Nikki 621266

Throttle bore diameter 24 mm (0.94 in.) 26 mm (1.02 in)

Venturi diameter 18 mm (0.71 in.) 21 mm (0.83 in)

Main Jet (MJ) L: #92, R: #95 #108 (L and R)

Pilot jet (PJ) #54 (L and R) #56 (L and R)

Main air jet (MAJ) ø1.4 ø1.4

Pilot air jet (PAJ) ø1.1 ø1.1

Pilot air screw turns out (PS) 1 5/8 1 1/4

(Idle mixture screw turns out)

Float level Float parallel to carburetor body

Idle Speed: (1)

Low idle speed 1550 r/min (rpm)

High idle speed 3600 r/min (rpm)

Air Cleaner:

Type Dual stage ﬁltration system

Pre-cleaner Foam element

Second-stage cleaner Paper element

Fuel:

Fuel requirement Unleaded regular grade gasoline

Fuel Pump:

Type Pulse-diaphragm pump

Governor:

Type Flyweight all speed governor

(1) Idle speeds may vary depending on each equipment. Refer to the equipment speciﬁcation.

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FUEL SYSTEM 2-5

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]

Control Panel Mounting Bolts [C]

•Remove the control panel assembly [A] while unhooking the governor

spring [B] end loop at the panel bracket.

•Clear the choke link rod end from the choke lever [C].

Control Panel Assembly Installation

•Before installing the control panel assembly, check to see that the

choke lever [A] and engine speed control lever [B] move smoothly in

all directions.

If any part is worn or damaged, replace the control panel assembly.

•After installation, adjust the low idle speeds and high idle speeds

to the speciﬁcations (see Low Idle Speed and High Idle Speed

adjustment).

Governor Arm Removal

•Remove:

Control Panel Assembly

•Loosen the clamp nut [A] and take off the governor arm [B].

•Unhooking the throttle link rod spring [C] end loop and clear the

throttle link rod end [D].

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2-6 FUEL SYSTEM

Governor Link Mechanism

Governor Arm Installation

•Insert the jig pin (2 mm dia) [I] through the jig pin hole of governor

shaft [B].

•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.

•Loosen the clamp nut [F] on the governor arm enough to move the

governor shaft.

•Turn the top end of the governor arm counterclockwise to fully open

the carburetor [G] throttle valve and hold it there.

•Using the jig pin [I], turn the governor shaft counterclockwise, fully

turn the shaft to end of its travel.

•Tighten the clamp nut.

Torque - Governor Arm Clamp Nut: 7.8 N m (0.80 kgf m, 69 in lb)

•Be sure the governor shaft extend from the governor arm is approxi-

mately 6.5 mm (0.26 in) [H] as shown.

•Remove the jig pin [I].

•Install the control panel assembly, and connect the governor arm with

the governor spring.

Governor Assembly Removal

•Remove the crankcase cover (see Camshaft/Crankshaft chapter).

•Remove the push rod. (see Engine Top End chapter)

•Upside down the engine.

•Remove the camshaft [A].

•Remove:

Washer [A]

Snap Ring [B]

Sleeve [C]

Governor Plate [D]

Snap Ring [B]

Steel balls [E]

Ball Guide [F]

Ball Plate [G]

Governor Assembly Installation

•Fit the snap rings [A] into the grooves securely.

•Spin the governor plate by hand and check that the steel balls and

governor plate operate freely.

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FUEL SYSTEM 2-7

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.

NOTE

It is not necessary to remove the governor shaft unless it is being

replaced.

•Replace the oil seal only if the lip shows signs of leakage or it has

been damaged.

•When replacing the oil seal [A] of the governor shaft, note the

following.

Install the oil seal into the crankcase cover [B] after the governor shaft

is inserted in the cover, and so that the marks [C] face out.

The depth [D] is 0 2mm(0 0.08 in.).

Governor Shaft Installation

•Apply engine oil to the governor shaft.

•Insert the governor shaft into the crankcase.

•Install the governor shaft plate [A] to the shaft [B] as shown.

Torque - Governor Shaft Plate Screws: 2.0 N m (0.20 kgf m, 17 in lb)

•Check that the governor shaft moves freely in its operating range.

NOTE

If the oil seal is removed, oil seal is put on after shaft is installed.

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2-8 FUEL SYSTEM

Carburetor

Fuel and Air Flow

The main system of the carburetor consists of the main jet [A], Valve

seat [B] main nozzle [C], and the main air passage [D] (main air jet

[E]). The main system meters fuel to the engine during moderate to

heavy load conditions. Fuel ﬂows through the main jet and into the

main nozzle, where it is joined by air from the main air passage (main

air jet). The resulting mixture ﬂows out the end of the main nozzle into

the carburetor bore, where it is atomized by the high speed air ﬂow, and

carried into the engine.

The pilot system includes the pilot jet [F], pilot air screw [G] (Idle

mixture screw), pilot air jet [H], pilot outlet [I], and the bypass holes [J].

The pilot system meters the fuel/air mixture while the engine is idling

and running under a light load. Under these conditions there is very

little air ﬂow through the carburetor bore; so little that it is not enough

to draw fuel through the main system of the carburetor and atomize

it. Instead, the fuel is drawn through the pilot system, since the nearly

closed throttle valve [K] causes high speed air ﬂow past the pilot outlet

and bypass holes (even at low engine speed).

Fuel ﬂow in the pilot system is metered by the pilot jet. Air for better

atomization is admitted via the pilot air jet in the mouth of the carburetor.

The fuel/air mixture passes into the bore of the carburetor side stream

of the throttle valve through the bypass holes and pilot outlet. While

the throttle valve is almost closed, it covers the small bypass holes

opening into the bore from the pilot system. As the throttle valve begins

to open, it uncovers the bypass holes, allowing more fuel/air mixture to

ﬂow. The extra ﬂow is needed because the engine starts to run faster

as the throttle is opened. The pilot screw controls the amount of fuel/air

mixture allowed through the pilot outlet, but does not meter the bypass

holes. A moderate amount of air comes in around the throttle valve at

an idle, so adjusting the pilot screw changes the fuel/air ratio. Turning

the pilot screw (Idle mixture screw) out (Counterclockwise) enrichens

the mixture; turning it in (clockwise) leans the mixture.

Main Fuel Flow

Pilot Fuel Flow ⇒

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FUEL SYSTEM 2-9

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 valve seat [B] simultaneously when

the switch key turned to the “OFF” position.

The valve opens automatically when the switch key is turned to the

“Run” position.

Low Idle Speed Adjustment

•Disconnect all possible external loads from the engine.

•Start the engine and warm it up thoroughly.

Always keep your hands clear of the moving parts.

•Move the throttle lever on dash to the idle position, and hold the

throttle lever on the carburetor in closed position (turn the governer

arm clockwise all the way) and adjust the low idle speed screw [A]

until the engine idles at speciﬁed speed.

Idle Speed (Carburetor idle rpm)

1450 rpm

•Release the throttle lever and adjust the low idle speed set screw [B]

on the control plate to obtain the speciﬁed governed low idle speed.

Low Idle Speed (Governed idle rpm)

1550 rpm

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2-10 FUEL SYSTEM

Carburetor

High Idle Speed Adjustment

NOTE

High idle speed adjustment should be made after the idle speed

adjustment is performed.

CAUTION

Do not adjust high idle speed with the air cleaner removed.

•Start and warm up the engine thoroughly.

Always keep your hands clear of the moving parts.

•Move the throttle lever at a dash to the high idle position and match

the lever hole position with the panel hole by inserting 6 mm dia., pin

or bolt [A].

•Loosen two M6 control panel mounting bolts [B] enough to move the

control panel assembly.

•Carefully move the control panel assembly right side [C] up or down

to obtain the speciﬁed high idle speed.

High Idle Speed

3600 rpm

•Tighten the M6 mounting bolts.

Torque - Control Panel Mounting Bolts: 5.9 N m (0.60 kgf m, 52 in lb)

•Remove the 6 mm dia., pin or bolt.

•Check the idle speed, and readjust the idle speed if necessary.

CAUTION

Be sure to make the idle and high idle speeds respectively

correspond to those of the equipment.

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FUEL SYSTEM 2-11

Carburetor

High Altitude Operation

At high altitude, the standard carburetor air-fuel mixture will be

excessively rich. Performance will decrease, and fuel consumption will

increase. High altitude performance can be improved by installing a

smaller diameter main-jet in the carburetor and correct idle speed.

NOTE

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 FH601D, FH641D FH680D, FH721D

0 ~ 1000 m (0 ~ 3000 ft) L:#92 R: #95 #108: L and R

1000 ~ 2000 m (3000 ~

6000 ft)

L: #89 R: #92 #105: L and R

2000 m (6000 ft) and higher L: #86 R: #89 #102: L and R

Main Jet Replacement

•Place the engine (equipment) on a level surface.

•Close the fuel shut off valve in the equipment.

•Drain the fuel in the carburetor completely by unscrewing the drain

screw at the bottom of the ﬂoat chamber.

•Remove the carburetor (see Carburetor Removal).

•Unscrew the main jet plugs [C] and take off the main jet plugs and

gaskets.

•Make sure that “L” [L] or “R” [R] mark on the ﬂoat chamber is shown

the main jet position.

•Using a proper blade screw driver, carefully replace the main jet [D]

with a new one for altitude expected.

•Tighten the main jet to the speciﬁcation (see Carburetor Disassembly/

Assembly).

•Install the gasket and the main jet plug.

Torque - Main Jet Plug: 19 N m (1.9 kgf m, 14 ft lb)

Fuel System Cleanliness Inspection

Gasoline is extremely ﬂammable and can be explosive under

certain conditions. 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.

•Remove the air cleaner. (see Cleaner Body Removal)

•Connect a plastic tube [A] to the carburetor drain hole and place a

suitable container under the plastic tube other end.

•Turn out the drain screw [B] a few turns to drain the carburetor and

check to see if water or dirt has accumulated in the carburetor.

•Tighten the drain screw.

Torque - Drain Screw: 2.0 N m (0.2 kgf m, 18 in lb)

•If any water or dirt is found, clean the carburetor (see Carburetor

Cleaning), and fuel tank, and check the fuel ﬁlter.

Carburetor Removal

Gasoline is extremely ﬂammable and can be explosive under

certain conditions. 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.

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2-12 FUEL SYSTEM

Carburetor

•Remove:

Air Cleaner and Related Parts (see Cleaner Body).

•Turn the fuel shut off valve to the OFF position.

•Drain the carburetor.

•Disconnect the fuel tube at the fuel inlet joint [A] of the carburetor.

•Remove the carburetor mounting bolts [B] and nuts [C].

•Disconnect the solenoid valve lead terminal and remove the earth

terminal.

•Unhook the throttle link spring [B] at the throttle shaft lever [C] clip

end with a long nose plier.

•Unhook the throttle [D] and choke link rods [E] at the top ends of their

arms while pull off the carburetor.

Carburetor Installation

•Clean the mating surfaces of the carburetor and intake manifold, and

ﬁt the new gaskets.

•Take care not to bend the throttle and choke link rods during

installation. Make sure the link spring around the throttle link rod

is inplace and that it pulls the governor arm and carburetor throttle

shaft lever toward each other.

•Install the intake manifold [A], new gaskets [B], insulator [C], carbu-

retor [D] and intake pipe [E] sequence as shown.

•Tighten the carburetor mounting bolts and nuts.

Torque - Bolts and Nuts: 5.9 N m (0.6 kgf m, 52 in lb)

•Adjust:

Carburetor Pilot Screw

Idle Speed

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FUEL SYSTEM 2-13

Carburetor

Carburetor Disassembly/Assembly

•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 outside of choke valve and throttle

valves for assembling them.

•Replace the pilot screw in accordance with the following procedure if

necessary.

Carefully mark the position of the pilot screw limiter on the carburetor

body so that it can be installed and set to its original position later.

Remove the limiter. Be careful not to turn pilot screw at this point.

Turn the pilot screw clockwise and count the number of turns until

screw is gently seated in the pilot passage. Record the number of

turns needed to closed the screw.

Turn out the pilot screw to replace it with anew one.

Install the new pilot screw until the screw is gently seated. Then open

the screw the same number of turns as recorded prior to removal.

Align the limiter with the mark on the carburetor body to install, taking

care not to turn the pilot screw.

•Install the choke valve and throttle valve on the shaft as the out side

mark of them facing outside, and apply a small amount of a bondng

agent to the valve screw threads.

CAUTION

Do not apply too much bonding aent to the valve screws itself

may be ﬁxed.

•Drive the ﬂoat pin so that it’s big diameter side faces the throttle shaft

lever.

•The fuel inlet valve seat is pressed into the carburetor body and is

not replaceable.

•Assemble carburetor parts which recommended tightening torque.

(see Exploded View)

1. Limiter 16. Gasket

2. Pilot Screw 17. Pilot Jet

3. Spring 18. Pilot Jet

4. Screw 19. Plug, Main Jet

5. Choke Valve 20. Gasket

6. Choke Shaft 21. Main Jet (L)

7. Seal 22. Main Jet (R)

8. Screw 23. Gasket

9. Throttle Valve 24. Solenoid Valve

10. Throttle Shaft 25. Screws

11. Collar 26. Spring

12. Seal 27. Drain Screw

13. Float Valve

14. Pin

15. Float

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2-14 FUEL SYSTEM

Carburetor

Carburetor Cleaning

Clean the carburetor in a well-ventilated area, and take care

that there is no sparks or ﬂame anywhere near the working

area; this includes any appliance with a pilot light. Because

of the danger of highly ﬂammable liquids, do not use gasoline

or low ﬂash-point solvents to clean the carburetors.

CAUTION

Do not use compressed air on an assembled carburetor, or the

ﬂoats may be crushed by the pressure.

Remove as many rubber or plastic parts from the carburetor

as possible before cleaning the carburetor with a cleaning

solution. This will prevent damage to or deterioration of the

parts.

The carburetor body has plastic parts that cannot be removed.

Do not use a strong carburetor cleaning solution which could

attack these parts; instead, use a mild high ﬂash-point clean-

ing solution safe for plastic parts.

Do not use wire or any other hard instrument to clean carbu-

retor parts, especially jets, as they may be damaged.

•Disassemble the carburetor.

•Immerse all the metal parts in a carburetor cleaning solution.

•Rinse the parts in water and dry them with compressed air.

•Do not use rags or paper to dry parts. Lint may plug the holes or

passages.

•Blow air through the holes and fuel passages with the compressed

air. All holes must be open.

•Assemble the 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.

•Inspect the carburetor body for damage. Flange sealing surfaces

should be smooth and free of burns and nicks. Replace the gasket if

necessary.

•Turn the throttle and choke shafts to check that the throttle and choke

butterﬂy valves move smoothly.

If the valves do not move smoothly, replace the carburetor body and/

or throttle shaft and choke shaft assembly.

•Check the gasket on the carburetor body.

If the gasket is not in good condition, replace it.

•Check the other parts of the carburetor for wear or damage. Replace

the part if necessary.

•Clean and check the ﬂoat level as follows.

CAUTION

Do not push down on the ﬂoat during ﬂoat level checking.

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FUEL SYSTEM 2-15

Carburetor

•With the ﬂoat [A] assembly installed onto the carburetor body [B], hold

the carburetor upside down at eye level. Gently support the ﬂoat with

a ﬁnger and bring it down slowly so that the ﬂoat arm tab [C] just

touches the ﬂoat valve needle [D]. The ﬂoat lower surface [E] should

be parallel with the carburetor body mating surfaces [F].

If the ﬂoat position is not correct, replace it.

•Inspect the inlet needle 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.

If either the needle or the seat is worn or damaged, replace the ﬂoat

assembly and carburetor body as a set.

•Inspect the tapered portion [A] of the pilot screw [B] for wear or

damage.

If the pilot screw is worn or damaged on the taper portion, replace it.

•Check the spring for weakened condition, replace it, if necessary.

Fuel Shut-Off Solenoid Valve Test

•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.

NOTE

If may be necessary to push the plunger slightly for the plunger to

withdraw.

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2-16 FUEL SYSTEM

Intake Manifold

Intake Manifold Removal

•Remove:

Air Cleaner (see Cleaner Body Removal)

Fan Housing

Carburetor (see Carburetor Removal)

•Cut off the band [A] and harness and/or wire lead are released from

intake manifold.

•Remove the manifold mounting bolts [B] and the intake manifold [C].

Intake Manifold Installation

•Replace the intake manifold gasket with new ones.

•Clean the mating surfaces of the cylinders and intake manifolds and

ﬁt a new gaskets [A] direction as shown.

[B]. 12mm

•Install the intake manifold [B].

•Tighten the mounting bolts [C].

Torque - Intake Manifold Mounting Bolts: 5.9 N m (0.6 kgf m, 52 in lb)

•Install and tighten the band [A] around the manifold [B] and wirelead

[C] and/or harness [D].

Position the wire and/or harness on top of the manifold as shown.

•Cut excess the band off.

•Install the other removed parts.

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FUEL SYSTEM 2-17

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.

•Wipe the area dry and immediately apply a coating of zinc oxide

dissolved in wood alcohol. If a cracks is present, the coating will

become discolored at the defective area.

If a crack is present in the intake manifold, replace it.

•Inspect the gasket surfaces for burns and nicks.

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2-18 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.

Fuel Flow Test:

Gasoline is extremely ﬂammable and can be explosive under

certain conditions. 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.

•Disconnect the fuel pump outlet nozzle from the tube.

•Connect a suitable hose [A] to the outlet nozzle.

•Run the lower end of the hose into a container.

•Start the engine, Check the fuel ﬂow.

If fuel ﬂow is none or little, replace the fuel pump.

Check for clogged or damaged tubes and fuel ﬁlter. Replace the faulty

parts.

Fuel Filter Inspection

•Visually inspect the fuel ﬁlter [A].

If the ﬁlter is clear with no signs of dirt or other contamination, it is

OK and need not be replaced.

If the ﬁlter is dark or looks dirty, replace with a new one. Also check

the rest of the fuel system for contamination.

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FUEL SYSTEM 2-19

Air Cleaner

Element Removal

•Remove the air cleaner cover nut [A] and the air cleaner cover [B].

•Remove:

Foam Element [A]

Paper Element [B]

Element Installation

•Install the element correctly on the air cleaner body.

•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

NOTE

In dusty areas, the elements should be cleaned more frequently

than the recommended intervals.

Because of the danger of highly ﬂammable liquids, do not use

gasoline or a low ﬂash-point solvent to clean the element.

•Remove the foam element and the paper element.

•Clean the foam element [A] in a bath of detergent and water, and let

the element air-dry throughly before install it.

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2-20 FUEL SYSTEM

Air Cleaner

•Clean the paper element [A] by tapping it gently on a ﬂat surface to

remove dust. If the element is very dirty, replace it with a new one.

CAUTION

Do not use compressed air to clean the paper element. Do not

oil the paper or foam element.

Cleaner Body Removal

•Remove the elements. (see Element Removal)

•Remove the cleaner body mounting bolts [A], nuts [B], screws [C],

and holder bracket [D].

•Do not miss rubber seal [E].

•Pull the breather tube [A] off the hole of the cleaner body [B].

Cleaner Body Installation

•Insert the breather tube [A] from the crankcase into the hole [B] of

the cleaner body.

•Install the cleaner body on the intake pipe and bracket with mounting

bolts, nuts and screws.

Torque - Cleaner Body Mounting Bolts and Nuts: 5.9 N m (0.6 kgf m,

52 in lb)

Housing (Cover 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.

•Check that no foreign material is obstructing the air passage.

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COOLING SYSTEM 3-1

Cooling System

Table of Contents 3

Exploded View...................................................................................................................................................................3-2

Cooling Fan.......................................................................................................................................................................3-3

Cooling Fan Removal.................................................................................................................................................3-3

Cooling Fan Installation..............................................................................................................................................3-3

Cooling Fan Inspection...............................................................................................................................................3-3

Screen Clearance Adjustment....................................................................................................................................3-3

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3-2 COOLING SYSTEM

Exploded View

T1: 2.0 N m (0.2 kgf m, 18 in lb)

T2: 5.9 N m (0.6 kgf m, 52 in lb)

T3: 6.9 N m (0.7 kgf m, 61 in lb)

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COOLING SYSTEM 3-3

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.

If any mud or dust have stuck to the cooling fan, clean it.

•Cooling fan is cleaned by washing in detergent and water.

CAUTION

Do not clean the cooling fan in oil solvent. It may be damage

by oil solvent.

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.

F: Screws

G: Clearance 1 3mm

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ENGINE TOP END 4-1

Engine Top End

Table of Contents 4

Exploded View...................................................................................................................................................................4-2

Speciﬁcations....................................................................................................................................................................4-5

Cylinder Head....................................................................................................................................................................4-6

Compression Measurement.......................................................................................................................................4-6

Cylinder Head Assembly Removal.............................................................................................................................4-7

Cylinder Head Assembly Installation..........................................................................................................................4-7

Push Rod Removal....................................................................................................................................................4-8

Push Rod Installation.................................................................................................................................................4-8

Push Rod Inspection..................................................................................................................................................4-9

Valve Mechanism Removal/Installation......................................................................................................................4-9

Cleaning and Inspection...........................................................................................................................................4-10

Valves..............................................................................................................................................................................4-11

Valve Clearance Inspection......................................................................................................................................4-11

Valve Clearance Adjustment....................................................................................................................................4-11

Valve Seat Inspection...............................................................................................................................................4-12

Valve Seat Repair.....................................................................................................................................................4-12

Valve Head Thickness..............................................................................................................................................4-14

Valve Stem Runout...................................................................................................................................................4-15

Valve Stem Diameter................................................................................................................................................4-15

Valve Guide Inside Diameter....................................................................................................................................4-15

Valve Spring Inspection............................................................................................................................................4-15

Cylinder, Piston...............................................................................................................................................................4-16

Piston Removal ........................................................................................................................................................4-16

Piston Installation.....................................................................................................................................................4-17

Piston/Cylinder Seizure............................................................................................................................................4-18

Piston Cleaning........................................................................................................................................................4-19

Piston Ring and Ring Groove Wear.........................................................................................................................4-19

Piston Ring End Gap ...............................................................................................................................................4-20

Piston Pin, Piston Pin Hole, and Connecting Rod Wear.........................................................................................4-20

Piston Diameter........................................................................................................................................................4-21

Cylinder Inside Diameter..........................................................................................................................................4-21

Cylinder Boring and Honing.....................................................................................................................................4-21

Mufﬂer............................................................................................................................................................................. 4-23

Mufﬂer Removal.......................................................................................................................................................4-23

Mufﬂer Installation....................................................................................................................................................4-23

Inspection.................................................................................................................................................................4-23

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4-2 ENGINE TOP END

Exploded View

O: Apply engine oil.

T1: 6.9 N m (0.7 kgf m, 61 in lb)

T2: 9.8 N m (1.0 kgf m, 87 in lb)

T3: 28 N m (2.8 kgf m, 21 ft lb)

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ENGINE TOP END 4-3

Exploded View

G: Apply grease.

S: Follow the speciﬁc tightening sequence.

T1: 2.0 N m (0.2 kgf m, 18 in lb)

T2: 5.9 N m (0.6 kgf m, 52 in lb)

T3: 6.9 N m (0.7 kgf m, 61 in lb)

T4: 28 N m (2.8 kgf m, 21 ft lb)

T5: 22 N m (2.2 kgf m, 16 ft lb)

T6: 44 N m (4.5 kgf m, 33 ft lb)

1. FH721D Engine

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4-4 ENGINE TOP END

Exploded View

T1: 15 N m (1.5 kgf m, 11.0 ft lb)

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ENGINE TOP END 4-5

Speciﬁcations

Item Service Limit

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 Intake 5.95 mm (0.0234 in.)

Exhaust 5.93 mm (0.0233 in.)

Valve guide inside diameter Intake, Exhaust 6.08 mm (0.239 in.)

Valve spring free length Intake, Exhaust 31.0 in (1.22 in.)

Rocker arm push rod rounout Intake, Exhaust 0.5 mm (0.02 in.)

Cylinder, Piston

Piston diameter 74.99 mm (2.952 in.)

Piston ring/groove clearance Top 0.18 mm (0.007 in.)

Second 0.16 mm (0.006 in.)

Piston ring thickness Top, Second 1.40 mm (0.055 in.)

Piston ring end gap Top 0.65 mm (0.026 in.)

Second 0.78 mm (0.031 in.)

Oil 1.05 mm (0.041 in.)

Piston pin outside diameter 15.96 mm (0.628 in.)

Piston pin hole inside diameter 16.08 mm (0.633 in.)

Connecting rod small end inside diameter 16.05 mm (0.632 in.)

Cylinder inside diameter: Standard Cylinder 75.28 mm (2.964 in.)

0.50 mm Oversize 75.78 mm (2.983 in.)

Cylinder bore out of round 0.056 mm (0.0022 in.)

Item Standard

Valve clearance Intake, Exhaust 0.1 to 0.15 mm (0.004 to 0.006 in.)

Valve seating surface angle Intake, Exhaust 45

Valve seating surface width Intake 0.8 to 1.4 mm (0.03 to 0.06 in.)

Exhaust 1.1 to 1.6 mm (0.04 to 0.06 in.)

Valves guide inside diameter Intake, Exhaust 6.00 to 6.012 mm

(0.2362 to 0.2367 in.)

Cylinder bore diamter standard cylinder

Standard cylinder 75.18 to 75.20 mm

(2.960 to 2.961 in.)

0.50 mm Over size 75.68 to 75.70 mm

(2.979 to 2.980 in.)

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

Valve Seat Cutter, 45 - 35.0 : 57001-1116

Valve Seat Cutter, 32 - 33.0 : 57001-1199

Valve Seat Cutter, 32 - 30.0 : 57001-1120

Valve Seat Cutter, 45 - 30.0 : 57001-1187

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4-6 ENGINE TOP END

Cylinder Head

Compression Measurement

•Before measuring compression, do the following.

Be sure the battery is fully charged.

Thoroughly warm up the engine so that engine oil between the piston

and cylinder wall will help seal compression as it does during normal

running.

Stop the engine.

•Disconnect the spark plug caps of each cylinder and remove the spark

plugs.

•Attach the compression gauge assembly ﬁrmly into one plug hole.

Special Tool - Compression Gauge: 57001–221 [A]

Compression Gauge Adapter: 57001–1159 [B]

•Ground the spark plugs to the engine.

To avoid ﬁre, do not ground the spark plugs in proximity to the

plug holes. Keep the plugs as far away as possible from the

plug holes.

•Using the starter motor, turn the engine over with the throttle fully

open until the compression gauge stops rising; the compression is

the highest reading obtainable.

Cylinder Compression (MIN) 390 kPa (57 psi)

•Repeat the measurement to the other cylinder.

If the compression is higher than the speciﬁed value, the piston rings,

cylinder and valves are probably in good condition.

If the compression is too high, check the following.

1. Carbon build-up on the piston crown and cylinder head - clean off

any carbon on the piston crown and cylinder head.

2. Cylinder head gasket - use only the proper gasket. The use of a

gasket of incorrect thickness will change the compression.

3. Valve guides and piston rings - rapid carbon accumulation in the

combustion chamber may be caused by worn valve guides and/

or worn piston oil rings. This may be indicated by white exhaust

smoke.

If cylinder compression is lower than the (MIN), check the following:

1. Gas leakage around the cylinder head - replace the damaged

gasket and check the cylinder head warp.

2. Condition of the valve seating.

3. Valve clearance.

4. Piston/cylinder wear, piston seizure.

5. Piston ring, piston ring groove.

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ENGINE TOP END 4-7

Cylinder Head

Cylinder Head Assembly Removal

•Remove:

Air Cleaner (see Fuel System chapter)

Fan Housing (see Electrical System chpater)

Mufﬂer (see Mufﬂer Exhaust Pipe Removal)

Carburetor (see Fuel System chapter)

Intake Manifold (see Fuel System chapter)

Spark Plug

•Unscrew the rocker cover mounting bolts [A], and remove the cover

[B] and gasket.

•When removing the #1, #2 cylinder head, set each cylinder at T.D.C

[A] of power stroke in.

•Loosen the cylinder head bolts 1/4 turn in the sequence shown.

CAUTION

If the above procedure is not followed, the cylinder head may

be warped during removal.

•Repeat the sequence until all bolts are removed and lift off the cylinder

head assembly.

NOTE

Mark the push-rods so they can be installed in their original position

during assembly.

Cylinder Head Assembly Installation

•Clean the mating surfaces of the cylinder heads and cylinder.

•Install the push rods in their original positions on each cylinder. (see

Push Rod Installation).

•Install the knock pins.

•Set each cylinder at T.D.C [A] of power stroke in.

•Put a new gaskets and the cylinder head assemblies on each cylinder,

then let the cylinder heads with push rods aligned under the rocker

arms.

NOTE

As the head gaskets are coated with sealing agents, be careful not

to damage the surfaces.

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4-8 ENGINE TOP END

Cylinder Head

•Tighten the cylinder head bolts following the tightening sequence.

Torque - Cylinder Head Bolts: 25 N m (2.6 kgf m, 19.0 ft lb)

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.

•Check and adjust the valve clearance (see Valve Clearance Inspec-

tion, Valve Clearance Adjustment).

•Install the gasket and rocker cover.

Torque - Rocker Cover Mounting Bolts: 6.9 N m (0.70 kgf m, 61 in lb)

•Install the other removed parts.

Push Rod Removal

•Set each cylinder at T.D.C of power stroke.

•Remove the rocker covers. (see Cylinder Head Assembly Removal)

•Loosen the valve clearance adjusting nuts [A].

•Move the rocker arms [B] to clear the push rod [C] upper ends.

•Pull out the push rods.

NOTE

Mark the push rods so they can be installed in their original position

during assembly.

Push Rod Installation

•Set each cylinder at T.D.C of power stroke.

•Install the push rods [A] in their original positions on each cylinder.

To Install the push rod in a correct position on the tappet [B], insert

the push rod so end of the push rod is sliding down [C] along inside

wall [D] of the crankcase and position the push rod end on to the

tappet.

•Check that both intake and exhaust push rods on each cylinder are at

lowest position on the cam lobes [E], if not turn the ﬂywheel clockwise

one turn (360 ) and reset each cylinder at T.D.C of power stroke in.

•Be sure the end of the push rods are correctly seated on the tappets.

•Tighten the valve clearance adjusting nuts.

•Check and adjust the valve clearance.

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ENGINE TOP END 4-9

Cylinder Head

Push Rod Inspection

•Place the rocker arm push rod in V blocks that are as far apart as

possible, and set a dial gauge 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.

If the runout exceeds the service limit, replace the rod.

Rocker Arm Push Rod Runout

Service Limit: 0.5 mm (0.02 in.)

Valve Mechanism Removal/Installation

•Remove the cylinder head assembly. (see Cylinder Head Assembly

Removal)

NOTE

When removing the valve mechanism parts, note their position

so that they may be reinstalled in their original position during

assembly.

•Remove:

Valve Clearance Adjusting Nuts [A]

Rocker Arms [B]

•Support the valve head in the combustion chamber with a suitable

block.

•To remove the spring retainer [A], push down the spring retainer with

thumbs and remove the collets [B].

•Remove the spring [C] and valve [D] .

•Remove the stem seals [A].

NOTE

It is not necessary to remove the stem seal unless it is being

replaced.

Valve guide [B] is not replaceable, do no remove it.

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4-10 ENGINE TOP END

Cylinder Head

•Valve Installation.

Apply engine oil to the valve stem to avoid damaging the stem seal.

Check to see that the valve moves smoothly up and down in the

guide.

Check to see that the valve seats properly in the valve seat. If it does

not, repair the valve seat.

•Rocker Arm Installation

Apply engine oil to the spherical pivot seat area on the rocker arm.

Apply engine oil to the rocker arm where it touches the push rod and

valve stem end.

Install the rocker arm on the stud bolt, and screw in the pivot and

locknut on the stud bolt temporarily.

NOTE

Correct installation must be performed when adjusting the valve

clearance (see Valve Clearance Adjustment).

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.

•Clean the head in a bath of high ﬂash-point solvent and dry it with

compressed air.

Clean the cylinder head in a well-ventilated area, and take care

that there are no sparks or ﬂame anywhere near the working

area; this includes any appliance with a pilot light. Do not

use gasoline or a low ﬂash-point solvent to clean the cylinder

head. A ﬁre or explosion could result.

•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 mating surface. Replace

the cylinder head if the mating surface is badly damaged.

Cylinder Head Warp

Service Limit: 0.05 mm (0.002 in.)

•Check the cylinder head for cracks or other damage.

•Cracks not visible to the eye may be detected by coating the

suspected area with mixture of 25% kerosene and 75% light engine

oil.

•Wipe the area dry and immediately apply a coating of zinc oxide

dissolved in wood alcohol. If a cracks is present, the coating will

become discolored at the defective area.

•If a cracks is present in the cylinder head, replace it.

•Inspect the mating surface for burrs and nicks.

•Clean and inspect the rocker arm where it touches the push rod and

valve stem.

If the contact points [A] are worn or damaged, replace the rocker arm.

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ENGINE TOP END 4-11

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.

No.1 Cylinder:

The left projection [A] on the ﬂywheel is faced with the right leg [B]

on the #1 ignition coil [C] as shown.

Check the intake and exhaust valves are closed completely, if not turn

the ﬂywheel one turn (360 ) clockwise and face the left projection with

the right leg again.

No.2 Cylinder:

The left projection [A] on the ﬂywheel is faced with the right leg [B]

on the #2 ignition coil [C] as shown. Follow No.1 Cylinder alignment.

•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)

Intake, Exhaust 0.1 0.15 mm (0.004 0.006 in.)

Valve Clearance Adjustment

•Since valve repairs change the valve clearance, adjust the valve

clearance to the speciﬁcation.

•Assemble the cylinder head and install the cylinder head assembly

on the block (see Cylinder Head Installation).

•Turn the crankshaft proper direction until the piston is at TDC of the

compression stroke (described above).

•Loosen the lock screws [A] and valve clearance adjusting nuts [B].

•Insert a 0.10 mm (0.004 in.) thickness gauge [C] between the rocker

arm and valve stem, and tighten the adjusting nut until the thickness

gauge begin to bind between the rocker arm and valve stem end.

Use a sweeping motion with the thickness gauge while making this

adjustment.

Valve Clearance (when cold)

Intake, Exhaust: 0.1 0.15 mm (0.004 0.006 in.)

•Holding the adjusting Nut with a spanner, tighten the lock screw to

the speciﬁed torque.

Torque - Valve Clearance Lock Screws: 6.9 N m (0.70 kgf m, 61 in lb)

•Do not overtighten.

•Remeasure any clearance that was adjusted. Readjust if necessary.

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4-12 ENGINE TOP END

Valves

Valve Seat Inspection

•Remove the valve. (see Valve Mechanism Removal/Installation)

•Inspect the valve seats for damage.

If the seats are warped or distorted beyond reconditioning, replace

the cylinder head.

•Pitted or worn valve seats can be refaced. Lap the valves to the seats

after refacing.

•Coat the valve seat with machinist’s dye.

•Push the valve into the guide.

•Rotate the valve against the seat with a lapping tool.

•Pull the valve out, and check the seating pattern on the valve head.

It must be the correct width [A] and even all the way around.

NOTE

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)

Inlet 0.8 1.4 mm (0.03 0.05 in.)

Exhaust 1.1 1.6 mm (0.04 0.06 in.)

Valve Seat Repair

•Follow the manufacture’s instructions for use of valve seat cutters

Special Tools

Intake Valve:

Seat Cutter 45 - ø35.0 57001-1116

Outside Cutter 32 - ø33.0 57001-1199

Exhaust Valve:

Seat Cutter 45 - ø30.0 57001-1187

Outside Cutter 32 - ø30.0 57001-1120

Valve Seat Cutter Holder-ø6.0: 57001-1360

Valve Seat Cutter Holder Bar: 57001-1128

If the manufacture’s instructions are not available, use the following

procedure.

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.

3. Do not fail to apply engine oil to the valve seat cutter before

grinding the seat surface. Also wash off ground particles sticking

to the cutter with washing oil.

NOTE

Do not use a wire brush to remove the metal particles from the

cutter. It will take off the diamond particles.

4. Setting the valve seat cutter holder [A] in position, operate the

cutter [B] with one hand [C]. Do not apply too much force to the

diamond portion.

NOTE

Prior to grinding, apply oil to the cutter, and during the operation

wash off any ground particles sticking to the cutter with washing

oil.

5. After use wash the cutter with washing oil and apply a thin layer

of engine oil before storing.

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ENGINE TOP END 4-13

Valves

Marks Stamped on the Cutter:

The marks stamped on the back of the cutter represent the following.

1 Cutter number, selected from 1 to 12

30 Cutter angle [A]

37.5 Outer diameter of cutter [B]

KS8B Manufactured lot number

Operating Procedures:

•Clean the seat area carefully.

•Recondition the valve seats with the valve seat cutters (45 ,30) and

lap the valves.

•Check the seats for good contact all the way around with machinist’s

dye.

•Measure the seat width [A]. If it is more than the STD width, the

seating surface should be refaced.

•If the valve seating pattern is not correct, repair the seat.

•Coat the seat with machinist’s dye.

•Fit a 45 cutter [A] to the holder and slide it into the valve guide.

Resurface the valve seat with a 45 cutter, removing only enough

material to produce a smooth and concentric seat.

CAUTION

Do not grind the seat too much. Overgrinding will reduce

valve clearance by sinking the valve into the head. If the valve

sinks too far into the head, it will be impossible to adjust the

clearance, and the cylinder head must be replaced. Do not

turn the cutter counterclockwise or drop it against the seat, or

it will be dulled.

•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. Check the seat

width frequently to prevent over grinding.

NOTE

Keep the seat width as closely as possible to the STD width.

•Make a light pass with the 45 cutter to remove any possible burrs at

the edge of the seat.

•After resurfacing the seat, inspect for even valve seating.

Apply a machinist’s dye to the valve face, insert the valve, and snap it

closed against the seat several times. The valve surface should show

good contact all the way around. Be sure the valve seat is centered

on the valve face. The position of the valve in the seat is evident after

lapping the valve.

If the seat does not make proper contact, lap the valve into seat with

a vacuum cap tool.

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4-14 ENGINE TOP END

Valves

•Coat the face of valve sparingly with a ﬁne lapping compound.

•Use the vacuum cup tool [A], to grip top of the valve [B]. Rotate the

valve in a circular motion to lap the valve to the seat.

•Lift the valve slightly from the seat every 8 to 10 strokes, continue

lapping operation until a uniform ring appears around entire surface

of the valve face.

•When lapping is completed, wash all parts in solvent to remove

lapping compound. Dry the parts thoroughly.

•Note the position of the lapping mark on the valve face. The lapping

mark should appear on or near the center of the valve face.

•When the engine is assembled, be sure to adjust the valve clear-

ances. (see Valve Clearance Adjustment)

Valve Head Thickness

•Remove the valve (see Valve Mechanism Removal/Installation).

•Measure the thickness of the valve head.

If the valve head thickness (valve margin) [A] is less than the service

limit, replace the valve.

Valve Head Thickness

Service Limit (IN, EX): 0.35 mm (0.014 in)

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ENGINE TOP END 4-15

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.

Valve Stem Runout

Service Limit (IN, EX): 0.05 mm (0.002 in.)

Valve Stem Diameter

•Measure the diameter of the valve stem [A] in two directions at right

angles, at four different positions on the stem.

If any single measurement is less than the service limit, replace the

valve.

Valve Stem Diameter

Service Limit:

Intake: 5.95 mm (0.234 in.)

Exhaust: 5.93 mm (0.233 in.)

Valve Guide Inside Diameter

•Use a small bore gauge or a micrometer to measure the inside

diameter [A] of the valve guide [B] a three places down the length

of the guide.

If the measurement is more than the service limit, replace the cylinder

head with a new one.

Valve Guide Inside Diameter

Service Limit:

Intake, Exhaust 6.08 mm (0.239 in.)

Valve Spring Inspection

•Inspect the valve spring for pitting, cracks, rusting, and burns.

Replace the spring if necessary.

•Measure the free length [A] of the spring.

If the measurement is less than the service limit, replace the spring.

Valve Spring Free Length

Service Limit: 31.0 mm (1.22 in.)

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4-16 ENGINE TOP END

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.

•Push the connecting rod end into the cylinder, and pull the piston and

connecting rod out of the cylinder.

CAUTION

Note a location of the arrow match mark [A] on the piston head

in relation to K Mark [B] on the connecting rod.

No.1 cyl. K mark on the connecting rod is face to face with

No.2 cyl. K Mark on the connecting rod.

Keep parts together as a set.

•Remove one of the piston pin snap rings [A] with needle nose pliers

[B].

•Remove the piston by pushing the piston pin [A] out the side from

which the snap ring was removed.

•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 and then push up on the opposite side of the ring

[A] to remove it.

•Remove the 3-piece oil ring with your thumbs in the same manner.

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ENGINE TOP END 4-17

Cylinder, Piston

Piston Installation

•Install the expander [A] in the piston oil ring groove so that the

expander ends [B] touch together, never overlap.

•Install the upper and lower steel rails. There is no UP or Down to the

rails. They can be installed either way.

•Do not mix up the top and second rings.

•Install the second and top rings as shown.

The rings should turn freely in the grooves.

[A] Piston Head

[B] Top Ring

[C] Second Ring

•Align the piston and rings with the piston ring end gap as shown.

[A]. Arrow Match Marks

[B]. Top ring End Gap, Upper Steel Rail End Gap

[C]. 30 45

[D]. Second Ring End Gap, Lower Steel Rail End Gap

•Apply engine oil to the piston pins.

Assemble the pistons onto the connecting rods as follow:

No.1 cyl. Piston, align the arrow match mark on the piston head with

opposite the raised letters (K Mark) on the connecting rod.

No.2 cyl. piston, align the arrow match mark on the piston head with

K Mark on the connecting rod.

[A]. No.1 Cyl. Piston

[B]. No.2 Cyl. Piston

[C]. Arrow Match Marks

[D]. K Mark

[E]. Opposite K Mark

•When installing a piston pin snap ring, compress it only enough to

install it and no more.

Fit a new piston pin snap ring into the side of the piston so that the

ring opening [A] does not coincide with the notch [B] in the edge of the

piston pin hole.

CAUTION

Do not reuse the snap rings, as removal weakens and deforms

them. They could fall out and score the cylinder wall.

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4-18 ENGINE TOP END

Cylinder, Piston

•Apply engine oil to the piston skirt and the cylinder bore.

Using the piston ring compressor grip [A] and the belt [B], lightly tap

the top of the piston with a plastic mallet [C] to insert the piston and

connecting rod into the cylinder.

Special Tool - Piston Ring Compressor Grip: 57001–1095

Piston Ring Compressor Belt: 57001–1097

•Insert the piston and connecting rod so that the arrow match mark

[A] on the top of the piston is facing the ﬂywheel side [B].

CAUTION

The connecting rod and the connecting rod big end cap are

machined at the factory in the assembled state, so they must

be replaced together as a set.

•Apply engine oil to the inner surface [A] of the connecting rod big end

[B] and caps [C].

•Install the connecting rod big end caps on their original position on

each connecting rod big ends.

•Apply a small amount of engine oil to the thread [D] and seating

surface [E] of the cap bolts.

•Tighten the cap bolts.

Torque - Connecting Rod Big End Cap Bolts: 9.8 N m (1.0 kgf m, 87

in lb)

•Install:

•Camshaft (see Camshaft/Crankshaft chapter)

•Crankcase Cover (see Camshaft/Crankshaft chapter)

Piston/Cylinder Seizure

•In case of seizure, remove the piston.

•Visually inspect the cylinder and piston damage.

If there is only light damage, smooth the position with #400 emery

cloth. Remove the small aluminum deposits from the cylinder with

#400 emery cloth or light honing.

If the damage is severe, the both cylinders must be bored oversize

and oversized pistons installed.

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ENGINE TOP END 4-19

Cylinder, Piston

Piston Cleaning

•Remove the piston and piston rings (see Piston Removal).

CAUTION

Never clean the piston head with the engine assembled.

Carbon particles will fall between the piston and cylinder, and

damage the crankshaft bearings.

•Scrape the carbon off [A] the piston head.

•Use the scraping tools carefully. Do not gouge the piston head. To

avoid gouging, use scrapers that are made of a material that will not

cause damage.

•Clean the piston ring grooves [A] with a broken piston ring or other

suitable tools.

CAUTION

Be careful not to widen the ring grooves. Damaged ring

grooves will require piston replacement.

Piston Ring and Ring Groove Wear

•Clean the piston (see Piston Cleaning).

•Visually inspect the piston rings and ring grooves.

If the piston rings are worn unevenly or damaged, replace them.

If the ring grooves are worn unevenly or damaged, replace both the

piston and piston rings.

•Check ring grooves for wear by inserting a new ring in the proper

groove at several points around the piston.

•Measure the clearance between the top and second rings and their

grooves using a thickness gauge [A].

If the piston ring/groove clearance is greater than the speciﬁed value,

replace the piston.

Piston Ring/Groove Clearance

Service Limit

Top 0.18 mm (0.007 in.)

Second 0.16 mm (0.006 in.)

NOTE

The oil ring is a three piece assembled ring. Difﬁcult to measure

the ring groove clearance and thickness, visually inspect only.

•Measure the piston ring thickness [A].

Use a micrometer to measure at several points around the rings.

If any of the measurement are less than the service limit, replace the

entire set of rings.

Piston Ring Thickness

Service Limit

Top, Second 1.40 mm (0.055 in.)

NOTE

When using new rings in a used piston, check for uneven groove

wear. The rings should ﬁt perfectly parallel to the groove sides. If

not, replace the piston.

For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983

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4-20 ENGINE TOP END

Cylinder, Piston

Piston Ring End Gap

•Remove the piston rings.

•Push each ring (one at a time) in the cylinder bore to a point close

to the bottom of the cylinder bore.

Use the piston to push it in to be sure it is square.

•Measure the gap [A] between the ends of the ring [B] with a thickness

gauge.

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

Top 0.65 mm (0.026 in.)

Second 0.78 mm (0.031 in.)

Oil 1.05 mm (0.041 in.)

Piston Pin, Piston Pin Hole, and Connecting Rod Wear

•Remove the piston pin.

•Measure the diameter of the piston pin with a micrometer at several

points.

If the outside diameter is less than service limit, replace the piston

pin.

Piston Pin Outside Diameter

Service Limit: 15.96 mm (0.628 in.)

•Measure the inside diameter [A] of the piston pin hole at several points

on both side. Use a dial bore gauge.

If the inside diameter is more than the service limit, replace the piston.

Piston Pin Hole Inside Diameter

Service Limit: 16.08 mm (0.633 in.)

•Measure the inside diameter [A] of the small end of the connecting

rod at several points. Use a dial bore gauge.

If the inside diameter is more than the service limit, replace the

connecting rod.

Connecting Rod Small End Inside Diameter

Service Limit: 16.05 mm (0.632 in.)

For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983

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ENGINE TOP END 4-21

Cylinder, Piston

Piston Diameter

•Measure the outside diameter of the piston 12.5 mm (0.9 in.) 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.

Piston Diameter

Service Limit: 74.99 mm (2.952 in.)

Cylinder Inside Diameter

•Clean and measure the cylinder inside diameter.

Use a dial bore gauge to measure front-to-back and side-to-side at

the points shown ﬁgure.

If any of the cylinder bore measurements is greater than the service

limit, the cylinder must be bored to the next oversize and then honed

(see Cylinder Boring and Honing).

Cylinder Inside Diameter

Standard: 75.18 mm 75.20 mm

(2.960 2.961 in.)

Service Limit: 75.28 mm (2.964 in.)

0.5 mm Oversize: 75.68 75.70 mm

(2.979 2.980 in.)

Service Limit: 75.78 mm (2.983 in.)

Cylinder Bore Out-of-Round

Standard: 0.01 mm (0.0004 in.)

Service Limit: 0.056 mm (0.0022 in.)

Cylinder Boring and Honing

Always resize to exactly 0.5 mm (0.02 in.) over the standard bore

size.

If this is done accurately, the stock oversize rings and piston will ﬁt

perfectly and proper clearance will be maintained.

Resizing the cylinder bore can be done by reliable repair shop or by

using a drill press and honing tool.

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.

Fine Boring Bore Diameter

Oversize Bore Diameter

0.50 mm 75.65 to 75.68 mm

(2.978 to 2.979 in.)

Final Bore Diameter

Oversize Bore Diameter

0.50 mm 75.68 to 75.70 mm

(2.979 to 2.980 in.)

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4-22 ENGINE TOP END

Cylinder, Piston

Change to a honing stone for ﬁnishing, the ﬁnal bore diameter should

be as shown in the table.

Be sure the correct stone is used and the stone is not worn.

•Clean the cylinder at the top and bottom of the cylinder to remove

burns and pieces of the base and head gasket.

•Anchor the cylinder (block) on the drill press table before honing.

•Align the center of the cylinder bore to the press center. Set the press

to operate from 200 to 250 rpm.

•Connect the drive shaft to the hone and set the stop on the drill press

so the hone can only extend 20 to 25 mm (3/4 to 1.0 in.) above the

top or below the bottom of the cylinder liner.

•Rotate the adjusting nut (knob) on the hone until the stones contact

snugly against the cylinder wall at the narrowest point. “Do not Force”.

•Turn the stone by hand. If you cannot turn it, the stone is too tight.

Loosen the hone until it can be turned by hand.

•Be sure that the cylinder and hone are centered and aligned with the

drive shaft and drill spindle.

•Pour honing oil inside of the cylinder during the honing operation.

Start the drill press. Move the hone up and down in the cylinder

approximately 20 cycles-per-minute.

•Check the diameter of the cylinder bore regularly during honing, using

an inside micrometer.

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.

NOTE

Do not use gasoline, kerosene, or commercial solvent to clean the

cylinder bore. These ﬂuids only wash all the oil from the cylinder

wall. They do not remove the metal particles produced during

honing.

•Clean the cylinder thoroughly. Use soap warm water and clean rags.

Clean the cylinder wall for “white glove” inspection. A clean white rag

should not show soil from the cylinder wall.

•Dry the cylinder and coat with a engine oil.

CAUTION

The cylinder must be thoroughly cleaned after honing to

eliminate all grit.

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ENGINE TOP END 4-23

Mufﬂer

Mufﬂer Removal

•Remove the bolt [B] on the mufﬂer bracket.

•Unscrew the ﬂange nuts [A], and remove the mufﬂer. Use a

penetrating oil if necessary to break threads loose.

•Do not use unnecessary force when removing the mufﬂer assembly,

or they could become damaged or distored.

•Remove the gaskets.

Mufﬂer Installation

•Clean the mufﬂer ﬂanges to the exhaust port gasket surfaces and

install a new gaskets each time the mufﬂer installed.

•Install the gasket.

•Install the mufﬂer.

•To prevent mis-threading, ﬁnger tight the ﬂange nuts ﬁrst. Next tighten

the nuts.

•Tighten the nuts.

Torque - Mufﬂer Flange Nuts: 15 N m (1.5 kgf m, 11 ft lb)

•After installation, thoroughly warm up the engine, wait until the engine

cools down and retighten the bolts and nuts.

Inspection

•Inspect the mufﬂer for dents, cracks, rust and holes.

If the mufﬂer is damaged, it should be replaced for best performance

and least noise.

•Check the mufﬂer for distortion and/or loose internal components.

Loss of power could develop if the mufﬂer loose the internal compo-

nents restricting the exhaust ﬂow.

•Check for breaks in the seams and check weld at the junction of the

exhaust pipes and mufﬂer.

•Tap the mufﬂer with a plastic hammer to decarbonize.

For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983

www.mymowerparts.com

For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983

www.mymowerparts.com

LUBRICATION SYSTEM 5-1

Lubrication System

Table of Contents

Exploded View...................................................................................................................................................................5-2

Engine Oil Flow Chart.......................................................................................................................................................5-3

Speciﬁcations....................................................................................................................................................................5-4

Engine Oil, Oil Filter and Oil Cooler.................................................................................................................................5-5

Oil Level Inspection....................................................................................................................................................5-5

Oil Change.................................................................................................................................................................5-5

Oil Filter Removal.......................................................................................................................................................5-6

Oil Filter Installation....................................................................................................................................................5-6

Oil Cooler Removal-FH721D......................................................................................................................................5-6

Oil Cooler Installation–FH721D..................................................................................................................................5-6

Oil Cooler Cleaning–FH721D.....................................................................................................................................5-7

Pressurized Lubrication System.......................................................................................................................................5-8

Oil Pressure Measurement .......................................................................................................................................5-8

Oil Pressure Switch Inspection..................................................................................................................................5-8

Oil Pump, Relief Valve......................................................................................................................................................5-9

Oil Pump, Relief Valve Removal................................................................................................................................5-9

Oil Pump, Relief Valve Installation.............................................................................................................................5-9

Oil Pump, Relief Valve Inspection..............................................................................................................................5-9

Oil Screen....................................................................................................................................................................... 5-12

Oil Screen Removal.................................................................................................................................................5-12

Oil Screen Installation..............................................................................................................................................5-12

Cleaning and Inspection...........................................................................................................................................5-12

For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983

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5-2 LUBRICATION SYSTEM

Exploded View

O: Apply engine oil.

G: Apply grease.

S: Follow the speciﬁc tighening sequence.

SS: Apply silicone sealant.

1. Other than FH721D Engine

2. FH721D Engine

T1: 2.0 N m (0.2 kgf m, 18 in lb)

T2: 5.9 N m (0.6 kgf m, 52 in lb)

T3: 6.9 N m (0.7 kgf m, 61 in lb)

T4: See page 5–6.

T5: 25 N m (2.6 kgf m, 19 ft lb)

T6: 9.8 N m (1.0 kgf m, 87 in lb)

T7: 44 N m (4.5 kgf m, 33 ft lb)

For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983

www.mymowerparts.com

LUBRICATION SYSTEM 5-3

Engine Oil Flow Chart

For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983

www.mymowerparts.com

5-4 LUBRICATION SYSTEM

Speciﬁcations

Item Standard

Engine Oil:

Grade API Service Classiﬁcation: SF, SG, SH, or SJ class

Viscosity SAE40, SAE30, SAE10W-30 / SAE10W-40, or SAE5W-20

Capacity 1.4 L (1.5 US qt) [When oil ﬁlter is not removed]

1.6 L (1.7 US qt) [When oil ﬁlter is removed]

Level Between "H" and "L" marks on oil gauge

Oil Pressure 241 to 310 kPa (35 to 45 psi)

Oil Pressure Switch:

Detect pressure 98 kPa (14.2 psi)

Screw PT 1/8 pipe thread

Oil Filter By-pass Valve Openning

Pressure 78.5 to 117.5 kPa (11.4 to 17.1 psi)

Item Service Limit

Oil Pump:

Inner and outer rotor clearance 0.2 mm (0.008 in.)

Outer rotor outside diameter 40.470 mm (1.5933 in.)

Outer rotor thickness 9.830 mm (0.3870 in.)

Pump housing inside diameter 40.801 mm (1.6063 in.)

Pump housing depth 10.230 mm (0.4028 in.)

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

For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983

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LUBRICATION SYSTEM 5-5

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. Preoil the engine to force all air from the

internal oil passages and the oil ﬁlter.

•Fill fresh engine oil to the speciﬁed level (see Oil Level Inspection).

•Run the engine at slow speed 2 minutes.

•Stop the engine and check the oil level.

Oil Level Inspection

•Place the engine on a level surface and check the oil level.

•Clean area around oil gauge [A] before removing it.

•Remove the oil gauge and wipe it with a clean cloth.

•Insert the oil gauge into gauge hole [B] and let its plug ﬁrmly ﬁt into

the gauge hole, then check the oil level.

•The oil level should be the operating range (between “H” line and “L”

line) on the oil gauge.

If the oil level is near or below the “L” line, remove the oil ﬁller cap

[C] and add enough engine oil to bring oil level to the “H” line.

CAUTION

Do not ﬁll above the “H” line. Excess oil will cause a smoking

condition.

Use the same type and make of oil that is already in the engine.

NOTE

If the engine oil type and make are unknown, use any brand of the

speciﬁed oil to top up the level in preference to running the engine

with the oil level low. Then at your earliest convenience, change

the oil completely.

If the oil level is too high, remove the excess oil by loosening the drain

plug [D].

Oil Change

•Change the oil after ﬁrst 8 hours of operation. Thereafter change oil

every 100 hours.

•Start and warm up the engine so the oil will drain easily. Stop the

engine.

•Place the engine on a level surface.

•Place a suitable container under the engine.

•Remove the drain plug [A] and drain the oil.

Be careful of hot oil when drained. It may be hot enough to

burn you severely.

•Check the O-ring [B] at the drain plug for damage. Replace the O-

ring with a new one if it is damaged.

If the oil drain plug joint is removed, tighten it.

Torque - Oil Drain Plug Joint (Plastic) :17 N m (1.7 kgf m, 12.0 ft lb)

Oil Drain Plug Joint (Metal) :39 N m (4.0 kgf m, 29 ft lb)

•Install the drain plug with the O-ring and tighten it.

Torque - Oil Drain Plug (Plastic) :6.9 N m (0.70 kgf m, 61 in lb)

Oil Drain Plug (Metal) :20 N m (2.0 kgf m, 14.5 ft lb)

For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983

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5-6 LUBRICATION SYSTEM

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: API Service Classiﬁcation:

SF, SG, SH or SJ Class

Viscosity: SAE40, SAE30, SAE10W-30/SAE10W-40, or

SAE5W-20

Capacity: 1.4 L (1.5 US qt)

[When oil ﬁlter is not removed]

1.6 L (1.7 US qt)

[When oil ﬁlter is removed]

Level: Between "H" and "L" marks on oil gauge

NOTE

Some increase in oil consumption may be expected when a multi

grade engine oil (10W-30/10W-40, 5W-20) is used. Check the oil

level frequently.

Oil Filter Removal

•Using a strap wrench or oil ﬁlter wrench [A], remove the oil ﬁlter [B].

Special Tool - Oil Filter Wrench : 57001–1249

When unscrewing the oil ﬁlter, place a suitable container beneath the

oil drip tray to receive oil from the oil ﬁlter and oil passages in the

engine. Turn the ﬁlter counterclockwise to remove it

Oil Filter Installation

•Apply light ﬁlm of engine oil to the seal [A].

•Install new ﬁlter.

Turn the ﬁlter until the seal contacts mounting surface [B] of the

engine. Then turn the ﬁlter BY HAND (S) 3/4 turn more.

•Run the engine at slow idle speed 2 minutes. Check for leaks around

the engine.

•Stop the engine. Check the oil level (see Oil Level Inspection).

Oil Cooler Removal-FH721D

•Remove the oil ﬁlter (see Oil Filter Removal).

•Unscrew the moutng joing [A] and remove the oil cooler [B].

•Check the O-ring [C] in groove of the oil cooler for damage.

Replace the O-ring with a new one, if necessary.

Oil Cooler Installation–FH721D

•Instal the oil cooler with the mounting joint and tighten it.

Torque - Oil Cooler Mounting Joint: 44 N m (4.5 kgf m, 33 ft lb)

•Install the oil ﬁlter (see Oil Filter Installation).

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LUBRICATION SYSTEM 5-7

Engine Oil, Oil Filter and Oil Cooler

Oil Cooler Cleaning–FH721D

•Clean dirt off the outside ﬁns [A] with brush or with compressed air.

For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983

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5-8 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. A pressure relief valve is

used between the oil pump and oil ﬁlter to relieve excessive oil pressure

by returning excess oil to the crankcase (see Oil Flow Chart).

Oil Pressure Measurement

•Remove the oil pressure switch or oil passage plug from the

crankcase.

•Install an appropriately sized oil pressure gauge adapter [A] and oil

pressure gauge [B].

•Run the engine and allow warm up completely.

•Run the engine at fast idle speed and read the oil pressure gauge.

•Stop the engine.

•Remove the oil pressure gauge and adapter.

•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 kgf m, 87 in lb)

Oil Passage Plug : 3.9 N m (0.40 kgf m, 35 in lb)

If the oil pressure is below the speciﬁcation, inspect the oil pump and

relief valve.

If the oil pump and relief valve are not at fault, inspect the rest of the

lubrication system.

Oil Pressure

241 to 310 kPa (35 to 45 psi)

Oil Pressure Switch

PT 1/8 (Taper Pipe Threads)

Oil Pressure Switch Inspection

When the oil pressure falls below 98 kPa (14.2 psi), the oil pressure

switch activates the oil warning lamp to alert the operator or lubricating

problem.

•To check the oil warning system, insert the switch key into the “OFF”

position of the engine switch, then turn it to the “RUN” position. The

warning light must be illuminated.

•When the engine is running be sure the warning light is “OFF”.

If the warning light comes on, stop the engine immediately and check

the oil level.

•When starting the engine, note the warning light on dash carefully.

If the warning light is on in the started engine in spite of adequate oil

level, check the lead from the pressure switch to the warning light for

short circuit and/or check the pressure switch and replace damaged

part.

If the light is not on at the moment of the engine switch operation,

check all leads of the warning light circuit or bulb and replace

damaged parts.

For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983

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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).

•Take off the relief valve spring and ball.

•Disassemble the pump parts assembly.

[A] Pin

[B] Pump Gear

[C] Mounting Bolts

[D] Outer Rotor

[E] Inner Rotor

[F] Pump Shaft

[G] Relief Valve Ball

[H] Spring

[I] Pump Cover Plate

[J] 6 mm DIA Hole

Oil Pump, Relief Valve Installation

•Fill the rotor housing with engine oil for initial lubrication.

•Install the relief valve ball and spring in position, then install the pump

parts assembly in the crankcase cover.

NOTE

When Installing the pump parts assembly, align the 6 mm DIA hole

[A] on the cover plate with center of the relief valve.

•Install the mounting bolts and tighten them.

Torque - Oil Pump Cover Plate Mounting Bolts : 5.9 N m (0.60 kgf m,

52 in lb)

Oil Pump, Relief Valve Inspection

•Remove the oil pump (see Oil Pump, Relief Valve Removal).

•Visually inspect the pump gear, outer and inner rotor, and cover plate.

If there is any damage or uneven wear, replace them.

Check the clearance [A] between the inner and outer rotor with a

feeler gauge. Measure the clearance between the high point of the

inner rotor and the high point of the outer rotor.

If the measurement exceed the service limit, replace the rotors as a

set.

Inner and Outer Rotor Clearance

Service Limit: 0.2 mm(0.008 in.)

•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.

Outer Rotor Outside Diameter

Service Limit: 40.470 mm(1.5933 in.)

•Measure the thickness [B] of the outer rotor with a micrometer at

several points

If the rotor thickness is less than the service limit, replace both the

inner and outer rotor.

Outer Rotor Thickness

Service Limit: 9.830 mm(0.3870 in.)

For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983

www.mymowerparts.com

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.)

•Measure the depth [B] of the pump housing with a depth micrometer

at several points.

If any of measurement is more than the service limit, replace the

crankcase cover.

Pump Housing Depth

Service Limit: 10.230 mm(0.4028 in.)

•Measure the outside [A] diameter of the pump shaft with a micrometer

at several points.

If the diameter is less than the service limit, replace the pump shaft.

Pump Shaft Outside Diameter

Service Limit: 10.923 mm(0.4300 in.)

•Measurer the inside diameter [A] of the pump shaft bearing in the

crankcase cover with a inside micrometer at several points.

If the inside diameter is more than the service limit replace the

crankcase cover.

Pump Shaft Bearing Inside Diameter

Service Limit: 11.072 mm(0.4359 in.)

•Visually inspect the relief valve spring, steel ball and valve seat in the

crankcase cover.

If any rough spots are found during above inspection, wash the valve

clean with a high ﬂash-point solvent and blow out any foreign particles

that may be in the valve with compressed air.

Clean the parts in a well ventilated area, and take care that

there is no spark or ﬂame anywhere near the working areas.

Because of the danger of highly ﬂammable liquids, do not use

gasoline or low ﬂash-point solvents.

For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983

www.mymowerparts.com

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.

•Measure free length [A] of the spring with a vernier caliper.

If the free length of the spring is less than the service limit, replace

the spring.

Relief Valve Spring Free Length

Service Limit: 19.50 mm(0.77 in.)

For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983

www.mymowerparts.com

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 spacers [B] and pipe

[C].

•Push [D] the oil screen with thumbs and remove it.

Oil Screen Installation

•Clean the oil screen thoroughly whenever it is removed for any reason.

•Insert the oil screen [A] into slots [B] in the pipe [C], and install the

pipe on the crankcase cover with the mounting bolts and spacers.

Torque - Oil Screen Mounting Bolts: 5.9 N m (0.60 kgf m, 52 in lb)

Cleaning and Inspection

•Clean the oil screen with high ﬂash-point solvent and remove any

particles stuck to it.

Clean the screen in a well-ventilated area, and take care that

there is no spark or ﬂame anywhere near the working area.

Because of the danger of highly ﬂammable liquids, do not use

gasoline or low ﬂash-point solvents.

NOTE

While cleaning the screen, check for any metal particles that might

indicate internal engine damage.

•Check the screen carefully for any damage: holes and broken wire.

If the screen is damaged, replace it.

For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983

www.mymowerparts.com

CAMSHAFT/CRANKSHAFT 6-1

Camshaft/Crankshaft

Table of Contents

Exploded View...................................................................................................................................................................6-2

Speciﬁcations....................................................................................................................................................................6-3

Crankcase.........................................................................................................................................................................6-4

Crankcase Cover Removal.........................................................................................................................................6-4

Crankcase Cover Installation.....................................................................................................................................6-4

Inspection...................................................................................................................................................................6-5

Cleaning.....................................................................................................................................................................6-6

Breather.............................................................................................................................................................................6-7

Breather Valve Removal.............................................................................................................................................6-8

Breather Valve Inspection..........................................................................................................................................6-8

Breather Valve Installation..........................................................................................................................................6-9

Camshaft, Tappet............................................................................................................................................................6-10

Camshaft, Tappet Removal......................................................................................................................................6-10

Camshaft, Tappet Installation...................................................................................................................................6-10

Camshaft Disassembly.............................................................................................................................................6-11

Camshaft Assembly..................................................................................................................................................6-11

Camshaft Inspection.................................................................................................................................................6-11

Camshaft Bearing/Journal Wear..............................................................................................................................6-11

Crankshaft, Connecting Rod...........................................................................................................................................6-13

Connecting Rod Removal........................................................................................................................................6-13

Connecting Rod Installation.....................................................................................................................................6-13

Crankshaft Removal.................................................................................................................................................6-13

Crankshaft Installation..............................................................................................................................................6-13

Cleaning/Inspection .................................................................................................................................................6-13

Connecting Rod Bend/Twist.....................................................................................................................................6-13

Connecting Rod Big End/Crankpin Width Wear......................................................................................................6-14

Connecting Rod Big End Bearing/Crankpin Wear...................................................................................................6-14

Crankshaft Runout....................................................................................................................................................6-15

Crankshaft Main Journal/Wear.................................................................................................................................6-15

Crankpin Resizing....................................................................................................................................................6-15

For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983

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6-2 CAMSHAFT/CRANKSHAFT

Exploded View

O: Apply engine oil.

G: Apply grease.

S: Follow the speciﬁc tightening sequence.

SS: Apply silicone sealant.

T1: 2.0 N m (0.2 kgf m, 18 in lb)

T2: 5.9 N m (0.6 kgf m, 52 in lb)

T3: 9.8 N m (1.0 kgf m, 87 in lb)

T4: 25 N m (2.6 kgf m, 19 ft lb)

T5: 44 N m (4.5 kgf m, 33 ft lb)

1. Other than FH721D Engine

2. FH721D Engine

For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983

www.mymowerparts.com

CAMSHAFT/CRANKSHAFT 6-3

Speciﬁcations

Item Service Limit

Camshaft, Tappet:

Cam lobe height Intake 29.621 mm (1.166 in.)

Exhaust 29.621 mm (1.166 in.)

Camshaft journal diameter PTO side 15.985 mm (0.6293 in.)

Flywheel side 15.985 mm (0.6293 in.)

Camshaft bearing inside diameter Crankcase 16.136 mm (0.6352 in.)

Crankcase cover 16.136 mm (0.6352 in.)

Crankshaft, Connecting Rod:

Connecting rod bend 0.15/100 mm (0.006/3.94 in.)

Connecting rod twist 0.15/100 mm (0.006/3.94 in.)

Connecting rod big end width 20.45 mm (0.805 in.)

Crankpin width 43.1 mm (1.697 in.)

Connecting rod big end inside diameter 40.044 mm (1.5765 in.)

Crankpin Outside diameter 39.940 mm (1.5724 in.)

Crankshaft runout 0.05 mm (0.002 in.) TIR

Crankshaft journal diameter PTO side 39.896 mm (1.571 in.)

Flywheel side 39.896 mm (1.571 in.)

Crankcase:

PTO shaft bearing inside diameter Crankcase cover 40.15 mm (1.581 in.)

Crankshaft journal bearing inside diameter Crankcase 40.15 mm (1.581 in.)

Sealant - Kawasaki Bond (Silicone Sealant): 56019–120

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6-4 CAMSHAFT/CRANKSHAFT

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)

•Unscrew the mounting bolts [A] and remove the crankcase cover [B]

from the crankcase.

There are two knock pins on the crankcase mating surface. A wooden

or plastic mallet may be used to gently tap loose the crankcase cover.

Crankcase Cover Installation

•Chip off 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 surfaces of the

crankcase and cover, and wipe dry.

Clean the crankcase and cover in a well-ventilated area, and

take care that there are no sparks or ﬂame anywhere near the

working area; this includes any appliance with a pilot light. Do

not use gasoline or a low ﬂash-point solvent to clean parts. A

ﬁre or explosion could result.

•Be sure to replace any oil seal removed with a new one.

Install the oil seal so that the marks [A] face out.

Pack some amount of a high temperature grease [B] into the space

between the seal lip [C] and dust lip [D]. Press in the new oil seal

using a press or suitable tools until it is ﬂush with ﬂange surface [E].

Do not damage the seal lips.

•When replacing the oil seal [A] of the governor shaft, note the

following.

Install the oil seal into the crankcase cover [B] after the governor shaft

is inserted in the cover, and so that the marks [C] face out.

The depth [D] is 0 2mm(0 0.08 in.).

•When installing the governor shaft and plate in the crankcase cover,

see Fuel System chapter.

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CAMSHAFT/CRANKSHAFT 6-5

Crankcase

•Check to see that the crankcase dowel pins [A] are in place on the

crankcase.

•Install the gasket [B] on the crankcase.

•Install the crankcase cover and tighten the crankcase cover bolts

following the tightening sequence shown.

Torque - Crankcase Cover Bolts: 25 N m (2.6 kgf m, 19.0 ft lb)

Do not turn one screw down completely before the others, as it may

cause the crankcase cover to warp.

Inspection

•Measure the inside diameter [A] of the PTO shaft bearing on the

crankcase cover at several points. This bearing is not replaceable.

Replace the crankcase cover if the inside diameter is more than the

service limit.

PTO Shaft Bearing Inside Diameter

Service Limit: 40.15 mm (1.581 in.)

•Measure the inside diameter [A] of the crankshaft journal bearing

on the crankcase at several points. This bearing is not replaceable.

Replace the crankcase if the inside diameter is more than the service

limit.

Crankshaft Journal Bearing Inside Diameter

Service Limit: 40.15 mm (1.581 in.)

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6-6 CAMSHAFT/CRANKSHAFT

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.

Clean the crankcase and cover in a well-ventilated area, and

take care that there is no spark or ﬂame anywhere near the

working area. Because of the danger of highly ﬂammable

liquids, do not use gasoline or low ﬂash-point solvents.

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CAMSHAFT/CRANKSHAFT 6-7

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. The blow-by gases are led to the breather chamber through the crankcase and the camshaft. Then, it is

drawn into the clean side of the air cleaner through the cylinder head and the hose and mixed with the clean air ﬂow, and

subsequently coming into the combustion chamber through the carburetor and the intake manifold.

Oil is primarily separated from the gases while passing through the inside of the rocker chamber from the crankcase,

and secondly separated from the gases in the breather chamber, and then returned back to the crankcase cover.

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6-8 CAMSHAFT/CRANKSHAFT

Breather

Breather Valve Removal

•Remove the bolts [A] and breather chamber cover [B].

•Remove the pipe [A].

•Remove the breather valve [B] unscrewing the mounting screws [A] at

the cam gear side of the crankcase (see Camshaft, Tappet Removal).

Breather Valve Inspection

•Visually inspect the reed valve [A] for breakage, hair cracks or

distortion, replace it if necessary.

•Visually inspect the back plate [B] for damage or rough contact

surface, replace it if necessary.

•Inspect the valve seating surface [C]. The surface should be free of

nicks or burrs.

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CAMSHAFT/CRANKSHAFT 6-9

Breather

Breather Valve Installation

•Be sure the drain hole [A] on the breather chamber does not

accumulate with slugs.

•Install the breather valve on the cam gear side of the crankcase (see

Camshaft, Tappet Removal).

Torque - Breather Valve Screws: 2.0 N m (0.2 kgf m, 18 in lb)

•Install a new gasket so the silicone bead side faces the crankcase

and the breather chamber cover, and tighten the bolts.

Torque - Breather Chamber Cover Bolts: 5.9 N m (0.6 kgf m, 52 in lb)

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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)

Rocker Covers [A]

•Position the piston TDC at the end of the compression stroke.

•Push down [A] the spring side of the rocker arm [B] and move it to

clear the push rod [C].

•Remove the push rods and mark them so they can be installed in

their original positions during assembly.

•Turn the crankcase up side down so that the tappets will fall away

from the cam lobes.

•Pull the camshaft [A] out of the crankcase.

•Remove the tappets [A] and mark them so they can be installed in

their original positions during assembly.

Camshaft, Tappet Installation

•Apply engine oil to the following.

Tappet Journal

Camshaft Journal

Cam Lobe Surface

Camshaft Gear

•Align the punch marks [A] on the crankshaft gear and camshaft gear.

•Install the washer [B] on the camshaft.

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CAMSHAFT/CRANKSHAFT 6-11

Camshaft, Tappet

Camshaft Disassembly

•Remove the governor assembly (see Fuel System chapter).

•Remove:

Spring [A]

Do not remove the ACR (automatic compression release) weight [B].

Camshaft Assembly

•Install the governor assembly (see Fuel System chapter).

•After assembling the camshaft, check the following items.

The governor plate [A] must move freely.

While shaking the camshaft, ACR weight [B] swings smoothly.

Camshaft Inspection

•Check the camshaft gear [A] for pitting, fatigue cracks, burrs or an

evidence of improper tooth contact.

Replace the shaft if necessary.

•Check the top of the cam lobes [B] for wear, burrs or uneven contact.

Replace the shaft if necessary.

Camshaft Bearing/Journal Wear

•Measure the height of each cam lobe.

If the cam height is less than the service limit for either lobe, replace

the camshaft.

Cam Lobe Height

Service Limit: IN. 29.621 mm (1.166 in.)

EX. 29.621 mm (1.166 in.)

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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.)

•Measure the inside diameter [A] of the camshaft bearing on the

crankcase at several points. This bearing is not replaceable.

Replace the crankcase if the inside diameter is more than the service

limit.

Camshaft Bearing Inside Diameter (Crankcase)

Service Limit: 16.136 mm (0.6352 in.)

•Measure the inside diameter [A] of the camshaft bearing on the

crankcase cover at several points. This bearing is not replaceable.

Replace the crankcase cover if the inside diameter is more than the

service limit.

Camshaft Bearing Inside Diameter (Crankcase Cover)

Service Limit: 16.136 mm (0.6352 in.)

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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.

•Drain the oil (see Lubrication System chapter).

•Remove:

Flywheel (see Electrical System chapter)

Camshaft (see Camshaft, Tappet Removal)

Connecting Rod and Piston Assembly (see Engine Top End chapter)

•Pull the crankshaft [A] out of the crankcase. Tap gently with a wooden

or plastic mallet if necessary to loosen the crankshaft.

Crankshaft Installation

•Clean up the crankshaft and crankcase thoroughly, especially at the

bearing contact surfaces.

•Pack some amount of high temperature grease into the oil seal on

the crankcase.

•Apply engine oil to the journal and bearing.

•Carefully insert the crankshaft ﬂywheel end into the main bearing and

oil seal in the crankcase.

Cleaning/Inspection

•After removing, clean the crankshaft and connecting rods with a high

ﬂash-point solvent and dry them with compressed air.

•Inspect the teeth of the crankshaft gear for pitting, fatigue cracks,

burrs and evidence of improper tooth contact.

Replace the gear if necessary.

•Inspect the crankshaft and connecting rods especially at the bearing

surfaces for wear, scratches, evidence of improper contact or other

damages.

Replace them if necessary.

Connecting Rod Bend/Twist

•Measure connecting rod bend.

Select an arbor of the same diameter as the connecting rod big end,

and insert the arbor through the connecting rod big end.

Select an arbor of the same diameter as the piston pin and at least

100 mm long, and insert the arbor through the connecting rod small

end.

On a surface plate, set the big-end arbor on V blocks.

With the connecting rod held vertically, use a height gauge to measure

the difference in the height of the small end arbor above the surface

plate over a 100 mm length to determine the amount of connecting

rod bend.

If connecting rod bend exceeds the service limit, the connecting rod

must be replaced.

Connecting Rod Bend

Service Limit: 0.15/100 mm (0.006/3.94 in.)

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6-14 CAMSHAFT/CRANKSHAFT

Crankshaft, Connecting Rod

•Measure connection rod twist.

With the big-end arbor still on the V blocks, hold the connection rod

horizontally and measure the amount that the small end arbor varies

from being parallel with the surface plate over a 100 mm length of

the arbor to determine the amount of connecting rod twist.

If connection rod twist exceeds the service limit, the connecting rod

must be replaced.

Connecting Rod Twist

Service Limit: 0.15/100 mm (0.006/3.94 in.)

Connecting Rod Big End/Crankpin Width Wear

•Measure the connecting rod big end width [A] with a micrometer or

dial caliper.

If the measurement is less than the service limit, replace the

connecting rod.

Connecting Rod Big End Width

Service Limit: 20.45 mm (0.805 in.)

•Measure the crankpin width [A] with a dial caliper.

If the crankpin width is more than the service limit, replace the

crankshaft.

Crankpin Width

Service Limit: 43.10 mm (1.697 in.)

Connecting Rod Big End Bearing/Crankpin Wear

•Apply a light ﬁlm of oil on the thread of the cap bolts.

•Install the cap bolts and tighten the bolts to the speciﬁed torque (see

Piston Installation in Engine Top End chapter).

•Measure the inside diameter [A] of big end at several points with a

telescoping gauge or inside micrometer.

If the inside diameter is more than the service limit, replace the

connecting rod with a new one.

Connecting Rod Big End Inside Diameter

Service Limit: 40.044 mm (1.5765 in.)

•Measure the crankpin outside diameter [A].

Use a micrometer to measure several points around the crankpin

circumference.

If the crankpin diameter is less than the service limit, replace the

crankshaft with a new one.

Crankpin Outside Diameter

Service Limit: 39.940 mm (1.5724 in.)

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CAMSHAFT/CRANKSHAFT 6-15

Crankshaft, Connecting Rod

Crankshaft Runout

•Measure the crankshaft runout.

Set the crankshaft in a ﬂywheel alignment jig or on V blocks gauge.

Set a dial gauge against both bearing journals.

Turn the crankshaft slowly to measure the runout. The difference

between the highest and lowest dial gauge readings (TIR) is the

amount of runout.

If the measurement exceeds the service limit, replace the crankshaft.

Crankshaft Runout

Service Limit: 0.05 mm (0.002 in.) TIR

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, replace the

crankshaft with a new one.

PTO Side Crankshaft Journal Diameter [A]

Service Limit: 39.896 mm (1.571 in.)

Flywheel Side Crankshaft Journal Diameter [B]

Service Limit: 39.896 mm (1.571 in.)

Crankpin Resizing

Crankpin can be resized to accept 39.5 mm (1.5551 in.) dia under

size connecting rod. The crankpin should be reground if the crankpin

is so much undersize and so much scored that a lapping operation will

prove unsatisfactory. Reground can be done by a reliable repair shop.

•Before sending the crankshaft, inspect the crankpin for cracks.

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

[A] 39.457 39.470 mm (1.5534 1.5539 in.)

[B] R 2.3 2.7 mm

[C] 43.0 mm MAX (1.693 in. MAX)

[D] 37.95 38.05 mm (1.4941 1.4980 in.)

•The crankpin surface should be concentric and parallel to each other

within 0.006 mm (0.0002 in.) full indicator reading.

•Finish the crankpin surface with a super ﬁnishing stone.

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ELECTRICAL SYSTEM 7-1

Electrical System

Table of Contents

Exploded View...................................................................................................................................................................7-2

Speciﬁcations....................................................................................................................................................................7-3

Wiring Diagram..................................................................................................................................................................7-4

Precautions....................................................................................................................................................................... 7-5

Charging, Ignition System.................................................................................................................................................7-6

Flywheel, Stator Coil Removal...................................................................................................................................7-6

Flywheel, Stator Coil Installation................................................................................................................................7-7

Charging System Operational Inspection...................................................................................................................7-9

Stator Coil Resistance................................................................................................................................................7-9

Unregulated Stator Output.........................................................................................................................................7-9

Regulator Removal...................................................................................................................................................7-10

Regulator Installation................................................................................................................................................7-10

Regulator Resistance...............................................................................................................................................7-10

Ignition Coil Removal...............................................................................................................................................7-13

Ignition Coil Installation............................................................................................................................................7-13

Ignition Coil Inspection.............................................................................................................................................7-14

Spark Plug Cleaning and Inspection........................................................................................................................7-14

Spark Plug Gap Inspection......................................................................................................................................7-14

Starter System................................................................................................................................................................7-15

Starter Motor Removal.............................................................................................................................................7-15

Starter Motor Installation..........................................................................................................................................7-15

Starter Motor Disassembly.......................................................................................................................................7-15

Starter Motor Assembly ..........................................................................................................................................7-16

Starter Motor Brush Inspection................................................................................................................................7-16

Brush Spring Inspection...........................................................................................................................................7-16

Armature Inspection.................................................................................................................................................7-16

Yoke Assembly Inspection........................................................................................................................................7-18

Pinion Clutch Inspection...........................................................................................................................................7-18

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7-2 ELECTRICAL SYSTEM

Exploded View

G: Apply grease.

SS: Apply silicone sealant.

T1: 3.4 N m (0.35 kgf m, 30 in lb)

T2: 5.9 N m (0.6 kgf m, 52 in lb)

T3: 9.8 N m (1.0 kgf m, 87 in lb)

T4: 15 N m (1.5 kgf m, 11 ft lb)

T5: 19 N m (1.9 kgf m, 14 ft lb)

T6: 22 N m (2.2 kgf m, 16 ft lb)

T7: 56 N m (5.7 kgf m, 41 ft lb)

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ELECTRICAL SYSTEM 7-3

Speciﬁcations

Item Standard Service Limit

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 26V AC/3000 rpm

Regulator resistance in the text

Ignition System:

Ignition coil:

Primary winding resistance in the text –––

Secondary winding resistance 8to11k –––

Spark Plug CHAMPION RCJ8Y –––

Plug gap 1.0 mm (0.040 in.) –––

Electric Starter System:

Starter motor:

Carbon brush length (with spring boss) 12.7 mm (0.500 in.) 6.4 mm (0.250 in.)

Commutator groove depth (approx) 2.0 mm (0.078 in.) 0.9 mm (0.035 in.)

Commutator diameter 31.7 mm (1.250 in.) 31.1 mm (1.225 in.)

Commutator runout ––– 0.4 mm (0.016 in.)

Special Tool - Hand Tester: 57001–1394

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7-4 ELECTRICAL SYSTEM

Wiring Diagram

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ELECTRICAL SYSTEM 7-5

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. A fully charged battery is a must for conducting

accurate electrical system tests.

The electrical parts should never be struck sharply, as with a hammer,

or allowed to fall on a hard surface. Such a shock to the parts can

damage them.

To prevent damage to electrical parts, do not disconnect the battery

leads or any other electrical connections when the engine switch is

on, or while the engine is running.

Because of the large amount of current, never keep the engine switch

turned to the start position when the starter motor will not turn over,

or the current may burn out the starter motor windings.

Take care not to short the leads that the directly connected to the

battery positive (−) terminal to the chassis ground.

Troubles may involve one or in some cases all items. Never replace

a defective part without determining what CAUSED the failure. If the

failure was brought on by some other item or items, they too must be

repaired or replaced, or the replacement part will soon fail again.

Make sure all connectors in the circuit are clean and tight, and

examine wires for signs of burning, fraying, etc. Poor wires and bad

connections will affect electrical system operation.

Measure coil and winding resistance when the part is cold (at room

temperature).

Electrical Connectors:

Female Connectors [A]

Male Connectors [B]

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7-6 ELECTRICAL SYSTEM

Charging, Ignition System

Flywheel, Stator Coil Removal

•Remove:

Screws [B] and Screen [A]

•Loosen the fan housing bolts [A] and remove the fan housing [B].

•Remove:

Bolts [A]

Ignition Coils [B] (see Ignition Coil Removal)

•Hold the ﬂywheel with a suitable tool [C], remove the ﬂywheel bolt

[B], washer, and bracket [A].

•Remove the bolts [A], plate [B] and fan [C].

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ELECTRICAL SYSTEM 7-7

Charging, Ignition System

•Using a suitable ﬂywheel puller [A], remove the ﬂywheel [B].

CAUTION

Always use ﬂywheel puller.

•Remove:

Woodruff Key [A]

Screws [B]

Stator Coil [C]

Flywheel, Stator Coil Installation

•Install the stator coil and tighten the screws.

Torque - Stator Coil Screws: 3.4 N m (0.35 kgf m, 30 in lb)

•Using a cleaning ﬂuid, clean off any oil or dirt on the following portions

and dry them with a clean cloth.

[A] Crankshaft Tapered Portion

[B] Flywheel Tapered Portion

•Fit the woodruff key [C] securely in the slot in the crankshaft before

installing the ﬂywheel.

•Install the ﬂywheel onto the crankshaft taper so that the woodruff key

ﬁts in the key way in the hub of the ﬂywheel.

•Install the fan [A] so that two positioning bosses [B] ﬁt around ﬂywheel

ignition magnet [C].

•Install the plate [D] so that the bosses [E] of the fan ﬁt in the holes of

the plate with bolts [F].

•Install the bracket [A] so that the notch [B] inserts into the slot [C] in

the ﬂywheel.

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7-8 ELECTRICAL SYSTEM

Charging, Ignition System

•Fit the conical washer [A] onto the ﬂywheel bolt [B], and tighten the

ﬂywheel bolt.

CAUTION

Make sure the direction of conical washer [A] for ﬂywheel bolt

[B]. Direction is as illustration.

Torque - Flywheel Bolt: 56 N m (5.7 kgf m, 41 ft lb)

[C] Bracket

[D] Flywheel

[E] Crankshaft

•Install the fan housing [A] and tighten the bolts [B] [C].

Torque - Fan Housing Bolts [B] (M8): 6.9 N m (0.70 kgf m, 61 in lb)

Fan Housing Bolts [C] (M6): 5.9 N m (0.60 kgf m, 52 in lb)

•Install the screen [A] and tighten the screen bolts [B].

Torque - Screen Bolt: 5.9 N m (0.60 kgf m, 52 in lb)

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ELECTRICAL SYSTEM 7-9

Charging, Ignition System

Charging System Operational Inspection

•Check battery condition.

NOTE

Always check battery condition before condemning other parts of

the charging system. The battery must be fully charged in order to

conduct accurate charging system tests.

•Warm up the engine to bring the components up to their normal

operating temperatures.

•Measure regulated output voltage at various engine speeds.

Connect a voltmeter across the battery terminals.

The readings should show nearly battery voltage when the engine

speed is low, and as the engine speed rises, the readings should

also rise. But they must stay within the speciﬁed range.

If the output voltage is much higher than the speciﬁcation, the

regulator is defective, or the regulator leads are loose or open.

If the output voltage dose not rise as the engine speed increase, the

regulator is defective or the alternator output is insufﬁcient for the

loads.

Regulated Output Voltage

Battery Voltage to 15 VDC

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

If the meter does not read as speciﬁed, replace the stator coil.

If the coil has normal resistance, but the voltage inspection showed

the alternator to be defective; the ﬂywheel magnets have probably

weakened, and the ﬂywheel must be replaced.

•Check for continuity between each stator pin and ground. There

should be no continuity (inﬁnite ohm).

If the stator coil fails any of these tests, replace the coil with a new

one.

Unregulated Stator Output

•Disconnect the connector [A].

•Connect AC voltmeter to the stator pins [B].

•Start the engine. Run the engine at the 3 000 rpm speed.

•Voltage reading should be minimum 26 VAC/3 000 rpm.

If the AC voltage reading is less than the speciﬁcation, replace the

stator.

Unregulated Stator Output (MIN)

26 VAC/3 000 rpm

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7-10 ELECTRICAL SYSTEM

Charging, Ignition System

Regulator Removal

•Remove:

Stator Coil Lead Connector [A]

Regulator Screw [B]

Regulator [C]

Regulator Installation

•Install the regulator and tighten the screws.

Torque - Regulator Screw: 3.4 N m (0.35 kgf m, 30 in lb)

Regulator Resistance

•Set the KAWASAKI Hand Tester selector switch to the R 100

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)

NOTE

Resistance value may vary with individual meters.

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ELECTRICAL SYSTEM 7-11

Charging, Ignition System

(With Charging Monitor type … 5 Blades)

If the resistance is not as speciﬁed replace the regulator.

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7-12 ELECTRICAL SYSTEM

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

a permanent magnet.

By rotating the ﬂywheel (magnetic poles) clockwise past the ignition module on a laminated core group, a voltage is

generated in the primary winding (L1).

This generates a small bias current to ﬂow through the control resistor (R1) to the base of (Q1). This base drive causes

the transistor to conduct (turns on) completing the primary circuit. Current ﬂows from the high side of the primary winding

through the transistor (collector to emitter) to ground.

The trigger sensor (TS1) senses the optimum time (peak current) to remove the base drive from the transistor (Q1).

This abrupt “turning off” of the transistor causes an interruption in current ﬂow which allows its associated ﬂux collapse,

and several hundred volts is induced through the primary winding (L1) inducing a very large voltage in the secondary

winding (L2). When the secondary voltage reaches several thousand volts the spark plug (SP) gap is ionized and ignition

occurs. The placement of the trigger sensor internal to the ignition insures constant timing over speed and temperature

and prevents counterclockwise operation.

The diode (D1) in the ignition shut off circuit blocks inadvertent application of battery voltage, protecting the internal

components of the ignition. With the stop switch (SW) in the closed position primary voltage is routed to ground, preventing

ignition operation.

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ELECTRICAL SYSTEM 7-13

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 bolt (2). While

tightening bolts, adjust the ignition coil air gap [A] between the three

legs of ignition coil and the two pole-plates to the speciﬁed value.

Ignition Coil Air Gap

Standard: 0.2 0.4 mm (0.008 0.016 in.)

Torque - Ignition Coil Bolts: 5.9 N m (0.6 kgf m, 52 in lb)

NOTE

Above procedure must be used to insure proper coil air gap is not

too large.

[A] Thickness Gauge

[B] Bolts

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7-14 ELECTRICAL SYSTEM

Charging, Ignition System

Ignition Coil Inspection

•Remove the ignition coils (see Ignition Coil Removal).

•Measure the primary winding resistance as follows:

Set the hand tester to the R 1k range.

Special Tool - Hand Tester: 57001–1394

Make the measurements shown in the table.

Ignition Coil Primary Winding Resistance

CAUTION

Use only Tester 57001–1394 for this test. A tester other than

the Kawasaki Hand Tester may show different readings.

If a megger or a meter with a large-capacity battery is used,

the ignition coil will be damaged.

•Measure the secondary winding resistance as follows:

Set the hand tester to the 1k range.

Connect the tester between the iron core [A] and plug cap terminal

[C].

Ignition Coil Secondary Winding Resistance:

811 k

If the tester does not read as speciﬁed, replace the coil.

Spark Plug Cleaning and Inspection

•Carefully pull the plug cap from the spark plug, and remove the spark

plug.

If the plug is oily or has carbon built up on it, clean the plug using a

high ﬂash-point solvent and a wire brush or other suitable tool.

If the spark plug electrodes are corroded or damaged, or if the

insulator is cracked replace the plug. Use the standard spark plug or

its equivalent.

[A] Insulator

[B] Center Electrode

[C] Plug Gap

[D] Side Electrode

Spark Plug Gap Inspection

•Measure the gap with a wire-type thickness gauge.

If the gap is incorrect, carefully bend the side electrode with a suitable

tool to obtain the correct gap.

Spark Plug Gap

Standard: 0.75 mm (0.030 in.)

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ELECTRICAL SYSTEM 7-15

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 kgf m, 11.0 ft lb)

Starter Motor Disassembly

•Remove:

Through Bolts and Nuts [A]

Brush Plate [B]

York [C]

Cap [D]

•While the collar [A] is pushing, remove the snap ring [B].

•Remove:

Spring [A]

Pinion Assembly [B]

Washer [C]

Bracket [D]

Armature [E]

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7-16 ELECTRICAL SYSTEM

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.

•Check the cap and replace it with a new one if damaged.

•Fit the projection [A] on the bracket into the notch [B] in the yoke.

•Press the springs and holding the brush leads with suitable clips.

•Put the washer [C] among the brushes.

•Fit the projection [D] on the brush plate into the notch [E] in the yoke.

Starter Motor Brush Inspection

•Measure the overall length of each brush [A].

If the brushes are shorter than the service limit, replace them.

Brush Length

Service Limit: 6.4 mm (0.25 in.)

Brush Spring Inspection

•Inspect the brush springs for pitting, cracks, rusting and burrs.

Replace the spring if necessary.

•Inspect the springs for weakened conditions and distortion.

Replace the springs if necessary.

If the brush springs are able to press the brushes ﬁrmly into place,

they may be considered serviceable. If they cannot, replace them.

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.

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ELECTRICAL SYSTEM 7-17

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

[B] Segment

[C] Good

[D] 0.9 mm (0.035 in.) limit

[E] Mica

•Measure the commutator outside diameter [A] at several points.

If the diameter is less than the service limit, replace the armature with

a new one.

Commutator Outside Diameter

Service Limit: 31.1 mm (1.225 in.)

•Support the armature in an alignment jig at each end of the shaft as

shown. Position a dial indicator perpendicular to the commutator.

•Rotate the armature slowly and read the commutator runout.

If runout is more than the service limit, turn down the commutator or

replace the armature with a new one.

Commutator Runout

Service Limit: 0.4 mm (0.016 in.)

•Measure the armature winding resistance.

Set the hand tester to the R 1 range and measure the resistance

between each segment [A] and all the others.

If the resistance it too high or even inﬁnite, the armature winding has

an open circuit. Replace the starter motor.

Armature Winding Resistance

Close to 0

•Set the hand tester to the R 1k range and measure the resistance

between the commutator and the armature shaft [B].

If the resistance is less than inﬁnite, the armature is shorted. Replace

the starter motor.

Commutator to Shaft Resistance

(∞)

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7-18 ELECTRICAL SYSTEM

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.

Yoke Assembly Inspection

•Set the hand tester to the R 1k range and measure the resistance

between the positive brush (es) [A] and brush plate [B].

If the resistance is less than inﬁnite, the positive brush is shorted to

ground. Replace the brush plate assembly.

Positive Brush to Ground Resistance

(∞)

•Set the hand tester to the R 1 range and measure the resistance

between the negative brush (es) [A] and brush plate [B].

If the meter does not read close to 0 , the brush plate is faulty.

Replace the brush plate assembly.

Negative Brush to Ground Resistance

Close to 0

Pinion Clutch Inspection

•Turn the pinion gear by hand. The pinion gear should turn clockwise

freely.

If the pinion clutch does not operate as it should, or if it makes noise,

replace the pinion clutch.

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TROUBLESHOOTING 8-1

Troubleshooting

Table of Contents

Engine Troubleshooting Guide..........................................................................................................................................8-2

Starter Motor Troubleshooting Guide................................................................................................................................8-6

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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.

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TROUBLESHOOTING 8-3

Engine Troubleshooting Guide

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8-4 TROUBLESHOOTING

Engine Troubleshooting Guide

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TROUBLESHOOTING 8-5

Engine Troubleshooting Guide

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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.

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!! FH601D FH641D FH680D FH721D KAWASAKI SERVICE REPAIR MANUAL 99924206002

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