Kawasaki FE290 User Manual To The E7933203 045b 4f54 B9ce 8c1cca4d5bd1

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FE120 FE170
FE250 FE290
FE350 FE400

4–stroke air-cooled gasoline engine

Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of
Quality Assurance Department/Consumer Products & Machinery Group/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been
taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such
changes to products manufactured previously.
All information contained in this publication is based on the latest product information available at the time of publication.
Illustrations and photographs in this publication are intended for reference use only and may not depict actual model
component parts.

First Edition (1) : Sep. 1, 2000 (K)

LIST OF ABBREVIATIONS
A
ABDC
AC
ATDC
BBDC
BDC
BTDC

C
DC
F

F
ft
g
h
L

ampere(s)
after bottom dead center
alternating current
after top dead center
before bottom dead center
bottom dead center
before top dead center
degree(s) Celsius
direct current
farad(s)
degree(s) Fahrenheit
foot, feet
gram(s)
hour(s)
liter(s)

lb
m
min
N
Pa
PS
psi
r
rpm
TDC
TIR
V
W

pound(s)
meter(s)
minute(s)
newton(s)
pascal(s)
horsepower
pound(s) per square inch
revolution
revolution(s) per minute
top dead center
total indicator reading
volt(s)
watt(s)
ohm(s)

Read OWNER’S MANUAL before operating.

EMISSION CONTROL INFORMATION
To protect the environment in which we live, Kawasaki has incorporated crankcase emission (1) and exhaust emission
(2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and
the 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 the 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

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 instructions or procedures which, if not correctly followed, could result in personal injury, or loss of
life.

CAUTION
This caution symbol identifies special instructions or procedures which, if not strictly observed, 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 interest for more efficient and convenient operation.
a procedural step or work to be done.
• Indicates
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.

GENERAL INFORMATION 1-1

General Information
Table of Contents
Before Servicing.................................................................................................................................................................1-2
General Specifications ....................................................................................................................................................... 1-4
Periodic Maintenance Chart...............................................................................................................................................1-6
Special Tools ......................................................................................................................................................................1-7
Exploded View....................................................................................................................................................................1-8

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.
(c) damage to electrical parts.
(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 nonpermanent 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.

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
Bent
Color change

Crack
Dent
Deterioration

Hardening
Scratch
Seizure

Warp
Wear

(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.

1-4 GENERAL INFORMATION
General Specifications
Item

FE120

FE170

Type D

Type G

Type D

Type G

Dimensions:
L

2W2H

Dry Weight

2 349 2 344
11.46 2 13.43 2 19.54

2 354 2 370
11.81 2 13.94 2 14.57

14.5

16.8

291

300

Engine:
Type of engine

Air cooled, 4-stroke, OHV, Single cylinder, Gasoline engine

Number of Cylinder
Bore

2 Stroke

in
Displacement

2.36

2 44
2 1.73

124

171

7.6

10.4
Counterclockwise facing PTO Shaft

Fast Idle Speed

rpm

Slow Idle Speed

rpm

4000
1600

Fuel information

Unleaded Gasoline
L

2.5

Lubrication system

SAE 10W30 (SF, SG, SH, or SJ)
Max.

0.6 L

Min.

0.35 L

Carburetor

0.35 L
Transistor Flywheel Magneto

Spark Plug

NGK BPR 5ES

Starting system

Recoil starter with ACR or electric starter

Governor
Air Cleaner

0.6 L
Float, Butterfly Type

Ignition system

Type of Reduction

3.4
Splash

Engine Oil
Oil Pan Capacity

2 50
2 1.97

66
2.60

cu.in
Direction of rotarion

Fuel tank capacity

Mechanical flyweight
---

1/2 gear reduction

---

Dual Element

Specifications are subject to change without notice, and may not apply to every country.

1/2 gear reduction

GENERAL INFORMATION 1-5
General Specifications
Item

FE250
Type D

FE290

Type G

Type D

FE350

Type G

Type D

FE400

Type G

Type D

Type G

Dimensions:
L

2W2H

344.5

13.56

2 395 2 432
15.55

17.01

363
14.29

2 408 2 441
16.06

378

17.36

2 422 2 454

14.88

16.61

17.87

2 422 2 459

378
14.88

16.61

18.07

Dry Weight
With recoil starter

26.8

30.4

34.4

34.5

With erectic starter

30.0

33.6

38.2

38.5

Engine:
Type of engine

Air cooled, 4-stroke, OHV, Single cylinder, Gasoline engine

Number of Cylinder
Bore

2 Stroke

mm
in

Displacement

76
2.99

2 55
2 2.17

78
3.07

2 67.5
2 2.66

3.43

249

286

351

401

17.5

21.4

24.5

Counterclockwise facing PTO Shaft

Slow Idle Speed

rpm

4000
1300

Fuel information

Unleaded Gasoline
L

5.3

Lubrication system

6.0

Splash

Engine Oil

6.4
Pressurized lubrication with oil filter

6.4

SAE 10W30 (SF, SG, SH, or SJ)
Max.

1.1 L

1.3 L

Min.

0.8 L

1.0 L

Carburetor

Float, Butterfly Type

Ignition system

Transistor flywheel magneto

Spark Plug

NGK BPR 5ES

Starting system

Recoil starter with ACR or electric starter

Governor

Mechanical flyweight
–

1/2 gear
reduction

Air Cleaner

2 65
2 2.56

15.2

rpm

Type of Reduction

83
3.27

Fast Idle Speed

Oil Pan Capacity

2 60
2 2.36

cu.in
Direction of rotation

Fuel tank capacity

–

1/2 gear

–

reduction

1/2 gear
reduction

Dual Element

Specifications are subject to change without notice, and may not apply to every country.

–

1/2 gear
reduction

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.

Always remove the spark plug cap from spark plug when servicing the engine to prevent accidental starting.
INTERVAL
MAINTENANCE

Check and add engine oil,
Check for loose or lost nuts and screws
Check for fuel and oil leakage
Check battery electrolyte level
Check or clean air intake screen
Tighten nuts and screws

Daily

First

Every

8
hr.

•
•
•
•
•

Clean air cleaner paper element
Clean fuel filter element
Change engine oil (with oil filer)
Clean and regap spark plug
Change oil filter
Replace air cleaner paper element
Clean dust and dirt from cylinder
and cylinder head fines
K Clean combustion chamber
K Check and adjust valve clearance
K Clean and lap valve seating surface

Every

100

200

300

hr.

•
•

Clean air cleaner foam element

Change engine oil (without oil filer)

Every

•
•

•
•
•

•

•
•
•
•
•

NOTE: The service intervals indicated are to be used as a guide. Service should be performed more frequently as
necessary by operating condition.
: Service more frequently under dusty conditions.
K: Have an authorized Kawasaki engine dealer perform those services.

GENERAL INFORMATION 1-7
Special Tools
Compression Gauge: 57001–221

Piston Ring Compression Grip: 57001–1095

Hand Tester: 57001–1394

Piston Ring Compression Belt,

50– 67: 57001–1096

Kawasaki Bond (Silicone Sealand): 56019–120

Piston Ring Compression Belt,

67– 79: 57001–1097

Piston RIng Pliers: 57001–115

Piston Ring Compression Belt,

80– 91: 57001–1320

1-8 GENERAL INFORMATION
Exploded View
FE120

GENERAL INFORMATION 1-9
Exploded View
FE170

1-10 GENERAL INFORMATION
Exploded View
FE250

GENERAL INFORMATION 1-11
Exploded View
FE290

1-12 GENERAL INFORMATION
Exploded View
FE350

SERVICE DATA 2-1

Service Data
Table of Contents
Service Specifications........................................................................................................................................................2-2
Adjustment Specifications ..................................................................................................................................................2-8
Tightening Torque Specifications ....................................................................................................................................... 2-9
Wiring Diagram.................................................................................................................................................................2-10
Troubleshooting ................................................................................................................................................................ 2-12
Starter Motor Troubleshooting and Actions...............................................................................................................2-17
Disassembly Sequence (FE120, 170)..............................................................................................................................2-18
Disassembly Sequence (FE250, 290, 350, 400).............................................................................................................2-19

2-2 SERVICE DATA
Service Specifications
Service Limit (mm)
Item

FE120
Type D

Compression (minimum)
with Recoil Starter
with Electric Starter
Cylinder
Bore (maximum)
Roundness (maximum)
Boring Size (oversize)
Crankcase Area
Crankshaft Bearing Bore (maximum)
Camshaft Bearing Bore (maximum)
Balancer Shaft Bearing Bore (maximum)
Oil Pump Housing Bore (maximum)
Oil Pump Housing Depth (maximum)
Oil Pump Shaft Bearing Bore (maximum)
Crankcase Cover
Camshaft Bearing Bore (maximum)

Type G

Crankshaft Journal Diameter
PTO Side (minimum)
Flywheel Side (minimum)
Balancer Link Rod Journal (minimum)
Shaft Runout: TIR (maximum)
Axial Play (maximum)

Camshaft
Camshaft Journal Diameter
PTO Side (minimum)
Flywheel Side (minimum)
Cam Lobe Height: Intake, Exhaust (minimum)
Axial Play (maximum)

Type D

Type G

FE250
Type D

Type G

290 kPa
(3 kg/cm2, 42 psi)
390 kPa
(4 kg/cm2, 57 psi)
60.067
(2.3648 in)
0.056
(0.0022 in)
0.50
(0.0120 in)

66.067
(2.3648 in)

76.070
(2.9949 in)

–––
15.063
(0.593 in)
–––

–––
16.063
(0.6324 in)
15.063
(0.5930 in)
–––
–––
–––
–––
16.063
–––

–––
20.063
(0.7899 in)
–––

–
–
–
–
15.063

–
–
–
–

–
–
–
–
–––

(0.5930 in)

Crankshaft
Crankpin Diameter (minimum)

FE170

(0.6324 in)

–
–
–
–
20.063

–
–
–
–

–
–
–
–
–––

(0.7899 in)

25.944
(1.0214 in)

28.944
(1.1395 in)

33.944
(1.3363 in)

19.930
(0.7846 in)
19.930
(0.7846 in)
–––
0.05
(0.0020 in)
0.5
(0.0197 in)

24.930
(0.9815 in)
24.930
(0.9815 in)
–––

29.930
(1.1783 in)
29.930
(1.1783 in)
–––

(standard: 0 ~ 0.24)

(standard: 0.03 ~ 0.30)

(standard: 0.05 ~ 0.17)

(0 ~ 0.0094 in)

(0.0012 ~ 0.0119 in)

(0.0020 ~ 0.0067 in)

0.35
(0.0138 in)

14.910

19.930

15.910

24.930

19.927

29.930

(0.5870 in)

(0.7846 in)

(0.6264 in)

(0.9815 in)

(0.7845 in)

(1.1783 in)

14.910
(0.5870 in)
26.157
(1.0298 in)
–––
0.50

15.910
(0.6264 in)
30.024
(1.1820 in)
–––
0.50

19.927
(0.7845 in)
31.040
(1.2220 in)
0.35
0.35

(0.0197 in)

(0.0138 in)

(standard:

(0.0138 in)
(standard:

0.08 ~ 0.34)

0.05 ~ 0.23)

0.05 ~ 0.17)

(0.0031 ~

(0.0020 ~

0.0134 in)

0.0091 in)

0.0067 in)

SERVICE DATA 2-3
Service Specifications
Service Limit (mm)
Item

FE120
Type D

Connecting Rod
Connecting Rod Big End Bore (maximum)

Type G

FE170
Type D

Type G

FE250
Type D

Type G

26.052
(1.0257 in)
14.042
(0.5528 in)
0.15/100
(0.006/100 in)

29.052
(1.1438 in)
16.047
(0.6318 in)

34.067
(1.3412 in)
18.051
(0.7107 in)

Dynamic Balancer
Balancer Shaft Journal Diameter
PTO Side (minimum)

–––

Flywheel Side (minimum)

–––

Connecting Rod Small End Bore (maximum)
Connecting Rod Bend and Twist (maximum)

Weight Guide Hole Bore (maximum)

–––

14.943
(0.5883 in)
14.933
(0.5883 in)
–––

Balancer Guide Diameter (minimum)
Link Rod Bearing Bore
Small End Bore (maximum)

–––

0.15
(0.0059 in)
0.12
(0.0047 in)
14.033
(0.5525 in)
13.975
(0.5502 in)

16.033
(0.6312 in)
15.975
(0.6289 in)

Big End Bore (maximum)
Piston
Piston Ring/Groove Clearance (with new rings)
Top Ring (maximum)
Second Ring (maximum)
Piston Pin Hole Bore (maximum)
Piston Pin Diameter (minimum)

–––
26.118
(1.0283 in)
25.907
(1.0200 in)
12.057
(0.4747 in)
47.106
(1.8546 in)

18.033
(0.7100 in)
17.975
(0.7077 in)

2-4 SERVICE DATA
Service Specifications
Service Limit (mm)
Item

FE290
Type D

Type G

Crankshaft Journal Diameter
PTO Side (minimum)
Flywheel Side (minimum)
Balancer Link Rod Journal (minimum)
Shaft Runout: TIR (maximum)
Axial Play (maximum)

Camshaft
Camshaft Journal Diameter
PTO Side (minimum)
Flywheel Side (minimum)
Cam Lobe Height: Intake, Exhaust (minimum)

Type D

Type G

FE400
Type D

Type G

290 kPa
(3 kg/cm2, 42 psi)
390 kPa
(4 kg/cm2, 57 psi)
78.067
(3.0735 in)
0.056
(0.0022 in)
0.50
(0.0197 in)

83.067
(3.2703 in)

30.075
(1.1841 in)
23.063
(0.9080 in)
–––
40.766
(1.6050 in)
10.170
(0.4004 in)
12.770
(0.5028 in)

35.075
(1.3809 in)

23.063

–––

(0.9080 in)

Crankshaft
Crankpin Diameter (minimum)

FE350

–––

23.063

87.067
(3.4278 in)

–––

(0.9080 in)

23.063

–––

(0.9080 in)

35.444
(1.3954 in)

37.444
(1.4742 in)

29.930
(1.1783 in)
29.930
(1.1783 in)
46.924
(1.8474 in)
0.05
(0.0020 in)
0.35
(0.013 in)

34.930
(1.3752 in)
34.930
(1.3752 in)
49.924
(1.9655 in)

0.35
(0.013 in)

(standard: 0.09 ~ 0.20)

(standard: 0.08 ~ 0.22)

(0.0035 ~ 0.0079 in)

(0.0031 ~ 0.0089 in)

(0.0031 ~ 0.0087 in)

22.927

29.930

22.927

34.930

22.927

34.930

(0.9026 in)

(1.1783 in)

(0.9026 in)

(1.3752 in)

(0.9026 in)

(1.3752 in)

22.927
(0.9026 in)
32.700
(1.2874 in)

33.240
(1.3087 in)

SERVICE DATA 2-5
Service Specifications
Service Limit (mm)
Item

FE290
Type D

Axial Play (maximum)

Connecting Rod
Connecting Rod Big End Bore (maximum)
Connecting Rod Small End Bore (maximum)
Connecting Rod Bend and Twist (maximum)
Dynamic Balancer
Balancer Shaft Journal Diameter
PTO Side (minimum)
Flywheel Side (minimum)
Weight Guide Hole Bore (maximum)
Balancer Guide Diameter (minimum)
Link Rod Bearing Bore
Small End Bore (maximum)
Big End Bore (maximum)
Piston
Piston Ring/Groove Clearance (with new rings)
Top Ring (maximum)
Second Ring (maximum)
Piston Pin Hole Bore (maximum)
Piston Pin Diameter (minimum)

–––

FE350

Type G

Type D

FE400

Type G

Type D

Type G

0.35

0.06

0.35

(0.013 in)

(0.024)

(0.013 in)

(standard:

0.07 ~ 0.21)

0.06 ~ 0.24)

0.07 ~ 0.21)

0.06~ 0.24)

0.07 ~ 0.21)

(0.0028 ~

(0.0024 ~

(0.0028 ~

(0.0024 ~

(0.0028 ~

0.008 in)

0.009 in)

0.008 in)

0.009 in)

0.008 in)

35.567
(1.4003 in)
19.051
(0.7500 in)
0.15/100
(0.006/100 in)

37.567
(1.4790 in)
20.051
(0.7894 in)

–––
–––
26.118
(1.0283 in)
25.907
(1.0120 in)

–––
–––
26.097
(1.0274 in)

12.064
(0.4750 in)
47.126
(1.8554 in)

12.057
(0.4747 in)
50.106
(1.9727 in)

0.16
(0.0063 in)
0.14
(0.0055 in)
19.033
(0.7493 in)
18.975
(0.7470 in)

20.033
(0.7887 in)
19.975
(0.7864 in)

–––
–––

2-6 SERVICE DATA
Service Specifications
Service Limit (mm)
Item

FE120
Type D

Piston Ring
Piston Ring Thickness (minimum)
Top, Second
Piston Ring End Gap (maximum)
Top, Second
Oil Ring
Cylinder Head
Valve Seating Surface Width
Standard
Maximum
Valve Guide Bore (maximum)
Intake, Exhaust
Rocker Arm Bearing Bore (maximum)
Gasket Surface Warp (maximum)
Rocker Arm Shaft Diameter (minimum)
Valve
Valve Stem Diameter
Intake Valve (minimum)
Exhaust Valve (minimum)
Valve Stem Runout (maximum)
Intake, Exhaust
Valve Head Thickness (minimum)
Intak, Exhaust
Valve Spring Free Length (minimum)
Intake, Exhaust
Rocker Arm Pushrod Runout (maximum)
Intak, Exhaust
HLA Device Leak-Dwon Dimension (maximum)
Intake, Exhaust
Valve Lift Height by ACR (minimum)
Exhaust
Oil Pump
Inner Rotor Shaft Diameter (minimum)
Outer Rotor
Diameter (minimum)
Width (minimum)
Inner/Outer Rotor Clearance (maximum)
Relief Valve Spring Free Length (minimum)
Breather Valve Air Gap (maximum)
Starter Motor
Carbon Brush Length (minimum)
Commutator Diameter (minimum)
Commutator Groove Depth (minimum)
*: Refer to Electric Starter System

Type G

FE170
Type D

Type G

1.42 (0.056 in)

FE250
Type D

Type G

1.44 (0.057 in)

1.0 (0.039 in)
Visual Inspection

0.7 (0.028 in)
1.7 (0.067 in)
5.562 (0.2190 in)
–––
0.05 (0.002 in)
–––

0.8 (0.031 in)
1.9 (0.075 in)

–––

6.065 (0.2388 in)
–––

–––

5.430 (0.2138 in)
5.415 (0.2132 in)

5.930 (0.2335 in)
5.915 (0.2329 in)

0.05 (0.002 in)

0.03 (0.001 in)

0.5 (0.020 in)

0.6 (0.024 in)

31.8 (1.252 in)

32.8 (1.291 in)

0.5 (0.020 in)

0.3 (0.012 in)

–––

–
–
–
–

0.6 (0.024 in)
–––
–––
–––
–––
–––
0.2 (0.008 in)
*
*
0.2 (0.008 in)

–
–
–
–

SERVICE DATA 2-7
Service Specifications
Service Limit (mm)
Item

FE290
Type D

Type G

FE350
Type D

Type G

1.44 (0.057 in)
1.2 (0.047 in)
Visual Inspection

0.8 (0.031 in)
1.9 (0.075 in)
7.065 (0.2781 in)
12.074 (0.4754 in)
0.05 (0.002 in)
11.949 (0.4704 in)

12.3 (0.484 in)

6.930 (0.2728 in)
6.915 (0.2722 in)
0.03 (0.001 in)
0.6 (0.024 in)
32.8 (1.291 in)

38.1 (1.500 in)

0.3 (0.012 in)

0.5 (0.02 in)

–––

0.5 (0.02 in)

0.6 (0.024 in)

1.0 (0.039 in)

12.627 (0.4971 in)
40.467 (1.5932 in)
9.920 (0.3906 in)
0.3 (0.012 in)
19.0 (0.748 in)
0.2 (0.008 in)
*
*
0.2 (0.008 in)

FE400
Type D

Type G

2-8 SERVICE DATA
Adjustment Specifications
Adjustment Specifications
Item
FE120
Idle Speed Setting
(crankshaft)

FE170

FE250

1600 rpm

FE290

FE350
FE400

1300 rpm

No-Load Maximum Speed Setting
(crankshaft)

4000 rpm

Valve Clearance:
Intake, Exhaust
(clearance on cold engine)
Spark Plug Electrode Gap

Adjustment
0.12 mm (0.0047 in)

0.7 ~ 0.8 mm (0.028 ~ 0.031 in)

Ignition Coil Air Gap
Standard:
Adjustment range:

0.3 mm (0.012 in)
0.25 ~ 0.4 mm (0.010 ~ 0.016 in)

unnecessary

SERVICE DATA 2-9
Tightening Torque Specifications
Tightening Torque Specifications

Unit: N1m (kg1m, ft1lb)
Tightening Torque

Tightening Location

FE350
FE120

FE170

FE250

FE290
FE400

Cylinder Head Bolts

25 (2.5, 18)

Connecting Rod Bolts
(Apply Oil to Threadss before Tightening)

(1.2, 8.9 in1lb)

(2.0, 15)

(2.3, 17)

137

Flywheel Retaning Nut
(thoroughly degrease tapered area)
Crankcase Cover

(6.5, 47)

Muffler Flange Nut

(1.0, 7.2)

(2.2, 16)

(3.2, 23)

–––

6.9

9.8

(0.7, 61 in1lb)

(1.0, 7.2)

–––

8.8

–––

(0.9, 78in1lb)

9.8 (1.0, 7.2)

Fan Retaining or Fan Presser Plate
Electric Starter Retaining Bolt

(14.0, 101)

Rocker Arm Lock Nut
Valve Clearance Adjustment Lock Nut

(8.8, 63)

9.8

20 (2.0, 15)
9.8 (1.0, 7.2)

15 (1.5, 11)

Oil Drain Plug

20 (2.0, 15)
32 (3.3, 24)

Spark Plug

23 (2.3, 17)

Fuel Tank

9.8 (1.0, 7.2)

Retaining Bolts for:
Fan Housing, Shroud, Recoil Starter

5.9 (0.6, 52 in1lb)

9.8 (1.0, 7.2)

General Bolts and Nuts:
M8

15 (1.5, 11)

5.9 (0.6, 52 in1lb)

3.4 (0.35, 30 in1lb)

1.2 (0.12, 11 in1lb)

Oil Level Sensor Bracket

9.8 (1.0, 7.2)

(M6 Tapping Screws)
Starter Motor Battery Terminal Nut

3.4

9.8

(0.35, 30 in1lb)

(1.0, 7.2)

–––
–––

2-10 SERVICE DATA
Wiring Diagram
Ignition Coil/Ignition Separate Type

SERVICE DATA 2-11
Wiring Diagram
Ignition Coil/Igniter Integrated Type

2-12 SERVICE DATA
Troubleshooting
If the engine malfunctions, first check whether th engine has been operated correctly. Then, systematically carry out
the troubleshooting procedure starting with simple items. This troubleshooting chart lists typical malfunctions. Do not
unnecessarily disassemble any parts before the cause of the problem is identified.

SERVICE DATA 2-13
Troubleshooting

2-14 SERVICE DATA
Troubleshooting

SERVICE DATA 2-15
Troubleshooting

2-16 SERVICE DATA
Troubleshooting

SERVICE DATA 2-17
Troubleshooting
Starter Motor Troubleshooting and Actions

the spark plug cap and ground the high-tension lead
• Remove
terminal.
• Perform an inspection by turning the key switch to the START position.

CAUTION
Do not touch the parts or accessories other than the starter
motor when troubleshooting the starter motor.
If the starter motor does not stop even when the key switch is
turned OFF, quickly disconnect the negative (–) lead from the
battery.

2-18 SERVICE DATA
Disassembly Sequence (FE120, 170)
Disassembly
Drain Plug
Fuel Tap, Fuel Tank
Spark Plug
Shroud
Muffler Assembly

Precaution
Warm up engine and drain oil.
Drain fuel before disassembly.

Remove flange retaining nuts.
Remove stay retaining bolt.

Air Cleaner
Carburetor
Governor Arm, Control Panel

Tighten it together with air cleaner case.

Fan Housing

Disconnect wire to stop switch.

Electrical:
• Ignition Coil
• Flywheel
Cylinder Head:
• Rocker Case
• Cylinder Head
Valve System:
• Pushrods
• Rocker Arms
• Exhaust Valve
Crankcase Cover

Camshaft
Tappets
Governor Shaft (Arm Pivot)
Connecting Rod Cap
Crankshaft
Piston/Connecting Rod Assembly
Connecting Rod

* FE120 uses M6 bolts.

Loosen boltss evenly in the reverse
order of tightening.
Identify intake and exhaust.
Identify intake and exhaust.
Loosen bolt evenly in the reverse
order of tightening.
for FE120
for FE170
Remove shaft from a position where
cam gear marks are aligned.
Identify intake and exhaust.
Remove snap ring and pull it out
of crankcase.
Remove from a position where it
does not interfere with connecting rod.
Pull it downward from cylinder bore.
Remove snap ring and pull piston pin out.

Assembly sequence (for FE120, 17):
Assembly parts in the reverse order of disassembly.

Bolt to be removed for tool
Name
14 across flats
17 across flats (tap)
M6 bolt (tank)
21 across flats
M6 bolt
M6 nut
M8 bolt
M5 butterfly bolt
M6 nut
M6 nut
M6 bolt
M6 bolt
(FE120 = 4)

Quantity
1
4
6
2
1
2
2
1
2
5

M5 bolt
M14 nut

2
1

M6 bolt
M8 bolt

4
4

M6 nut

M6 bolt
M8 bolt

8
7

Snap ring

10 across (bolt)

Snap ring

SERVICE DATA 2-19
Disassembly Sequence (FE250, 290, 350, 400)
Disassembly Area

Precaution

Drain Plug
Fuel Tap, Fuel Tank

Warm up engine and drain oil.
Drain fuel before disassembly.

Spark Plug
Muffler Assembly

Remove the exhaust pipe cover.
Remove the muffler assembly.

Wiring Related
Panel Control
Tank Bracket
Control Related:
• Link Rod and Spring
• Governor Arm
• Control Panel Assembly
Starter Motor
Air Cleaner
Carburetor

Disconnect ground wire.
Disconnect connecting terminals.
Remove it from tank bracket.

Also remove insulator.

Three-piece Shroud and Fan
Housing
Electrical:
• Ignition Coil
• Flywheel
• ACG
Cylinder Head:
• Rocker Case
• Cylinder Head
Valve System:
• Pushrods
• Rocker Arm

• Exhaust Valve
Crankcase Cover
Shaft Adjust Shims
Camshaft
Tappets (FE250, 290)
or HLA Devices (FE350, 400)
Governor Shaft (arm pivot)
Balancer Guide
Connecting Rod Gap
Crankshaft
Piston/Connecting Rod Assembly
Connecting Rod
Oil Pump
Oil Filter

Remove clamp and lead.
* FE350, 400 use M18 nut.

Bolt to be removed for tool
Name
14 across
M6 bolt (tap)
M6 bolt (tank)
21 across
M6 bolt
M6 nut (with washer)
M8 nut
M8 bolt
M8 nut
M5 screw
M8 bolt

M6 nut
M6 bolt
M8 bolt
M6 batterfly bolt
M6 nut
M6 bolt
M6 bolt
M6 tower bolt
M5 tapping screw
M5 bolt
*M16 nut
M6 screw

Quantity
1
6
2
1
2
1
1
4
4

1
2
2
2
2
1
15
1
2
2
1
2 or 4

Loosen bolts evenlly in reverse of tightening.

M6 bolt
M8 bolt

2
6

Identify intake and exhaust.
(Identification unnecessary for FE350, 400.)
Identify intake and exhaust.
* for FE250
* for FE290, 350, 400

M6 nut
E-ring

2
1

M8 bolt

Snap ring
M6 nut
12 across flats (bolt)

1
4
2

Snap ring
M6 bolt
M5 bolt

2
6
2

Identify shims for crankshaft and camshaft.
Remove shaft from a position where cam gear
marks are aligned.
Identify intake and exhaust.
Face snap ring side of HLA device upward.

Remove from to a position where it does not
interfere with connecting rod.
Pull it downward from cylinder bore.
Remove snap ring and pll piston pin out.
Remove plate.

Assembly sequence (for FE250, 290, 350, 400)
Assemble parts in the reverse order of disassembly.

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-1

Disassembly, Reassembly, Inspection, and Maintenance
Table of Contents
Carburetor....................................................................3-2
Construction and Function ................................... 3-2
Disassembly, Cleaning, and Reassembly Precautions ...................................................................... 3-3
Adjustment............................................................3-4
Carburetor with Fuel Cutoff Valve ........................ 3-6
Governor Mechanism..................................................3-7
Governor Operating Mechanism .......................... 3-7
Governor Gear Assembly Installation...................3-8
Governor Arm Installation (Setting the Governor)3-8
Air Cleaner.................................................................3-10
Element Cleaning............................................... 3-10
Cooling System ......................................................... 3-11
Fuel Tank and Filter...................................................3-12
Ignition System..........................................................3-13
Description of Function.......................................3-13
Spark Inspection.................................................3-14
Spark Plug Cleaning and Inspection..................3-14
Ignition Coil Inspection ....................................... 3-15
Igniter Inspection ................................................ 3-16
Flywheel Disassembly and Reassembly............3-17
Ignition Coil Reassembly (Air Gap Adjustment).3-18
Key Switch (engine switch) Inspection...............3-18
Charging System.......................................................3-19
Charging System Inspection...............................3-19
ACG Inspection...................................................3-19
Rectifier Inspection.............................................3-19
Regulator Inspection...........................................3-20
Starter System...........................................................3-21
Starter Motor Construction.................................3-21
Solenoid (Starter Motor) Wiring Inspection........3-22
Starter Motor Inspection.....................................3-23
Recoil Starter.............................................................3-25
Disassembly........................................................3-25
Reassembly........................................................3-25
Cylinder Head............................................................3-26
Compression Inspection.....................................3-26
Disassembly........................................................3-26
Cleaning and Inspection.....................................3-27
Reassembly........................................................3-27
Valve System.............................................................3-28
Hydraulic Lash Adjuster (HLA)...........................3-28
Valve Clearance Inspection and Adjustment......3-31
Automatic Compression Release (ACR) Device Inspection .............................................................. 3-32

Valve Disassembly and Reassembly..................3-32
Valve Guide Inspection.......................................3-33
Valve Inspection..................................................3-33
Valve Spring Inspection......................................3-34
Valve Seat Inspection and Lapping....................3-35
Valve Seat Correction.........................................3-35
Rocker Arm and Rocker Shaft............................3-36
Pushrod Inspection.............................................3-36
Piston and Connecting Rod ...................................... 3-37
Disassembly........................................................3-37
Reassembly........................................................3-37
Piston Inspection ................................................ 3-39
Piston Pin Inspection..........................................3-40
Piston Ring Inspection........................................3-40
Connecting Rod Inspection ................................ 3-41
Cylinder Block and Crankcase Cover ....................... 3-43
Cylinder Inspection.............................................3-43
Crankcase Cover................................................3-43
Ball Bearing ........................................................ 3-44
Oil Seal...............................................................3-45
Plain Bearing Area Inspection............................3-45
Lubrication System....................................................3-46
Lubrication Method.............................................3-46
Oil Pump Disassembly and Reassembly........... 3-47
Oil Pump Inspection ........................................... 3-48
Oil Level Warning Device ................................... 3-49
Breather..............................................................3-52
Air Filter (cartridge type).....................................3-52
Crankshaft ................................................................. 3-54
Disassembly........................................................3-54
Crankshaft Inspection.........................................3-55
Crankshaft Axial Play Adjustment ...................... 3-55
Reassembly........................................................3-56
Balancer.....................................................................3-57
Reciprocal Movement Balancer (FE400, 350, 290,
250).....................................................................3-58
Uniaxial Rotation Balancer (FE170)...................3-59
Camshaft ................................................................... 3-61
Disassembly........................................................3-61
Inspection ........................................................... 3-61
Reassembly........................................................3-62
Camshaft Axial Play Adjustment........................ 3-63

3-2 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Carburetor
Construction and Function
The function of a carburetor is to mix fuel and air by applying the
principle of an atomizer, thus creating an appropriate air-fuel mixture in
accordance with load fluctuations. The major functions of a carburetor
consist of the following four systems.
Pilot System
The function of this system is to supply fuel during the idling and the
low-speed, light-load operating conditions.
The fuel that is regulated by the pilot jet mixes with the air that is
regulated by the pilot air jet, and the resulting mixture is supplied via
the pilot port and bypass port to the engine.
The fuel that is used during idling is supplied primarily via the pilot
port.
A: Pilot Jet
B: Pilot Air Jet (Body Jet)
C: Pilot Port
D: Bypass Port
E: Pilot Screw
F: Pilot Port

Main system
The function of this system is to supply fuel during medium- to highspeed, high-load operating conditions. Fuel is regulated by the main jet
and flows through the main nozzle.
The air that is regulated by the main air jet intermixes with the fuel
via the bleed hole of the main nozzle, and is discharged into the venturi
in an emulsion form (in which the liquid is intermixed with air bubbles).
In the venturi, the airflow from the air cleaner causes the fuel to
become atomized, and the resulting air-fuel mixture is fed into the
cylinder.
Choke System
Closing the choke valve decreases the volume of air intake and
increases the intake vacuum during the intake stroke. As a result, a
greater volume of fuel than normal is discharged from the pilot and
main systems to facilitate the starting of a cold engine.
Float System
The function of the float is to maintain the fuel in the float chamber
of the carburetor at a constant level so that the proper amount of fuel
can be supplied to the engine.
Setting the fuel level in the float chamber to low makes it more difficult
for the carburetor to draw the fuel up to the venturi, resulting in a leaner
air-fuel mixture.
Setting the fuel level to high increases the volume of fuel that is drawn
up to the venturi, resulting in a richer air-fuel mixture
A: Main Jet
B: Main Nozzle
C: Main Air Jet (body jet)
D: Chocke Valve
E: Throttle Valve
F: Float Hinge Pin

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-3
Carburetor
An optimal fuel level is prescribed at the time the carburetor is
designed. Along with the fluctuations in the fuel level, the float moves
up and down in order to open and close the float valve. The flow of fuel
into the float chamber is enabled or stopped in this manner in order to
maintain the fuel level at the prescribed level.

CAUTION
The fuel level of the carburetor of the FE series engines cannot
be adjusted. Replace the float if it is defective.
The air pressure in the float chamber is constantly maintained at
atmospheric pressure via the air vent.
A: Float
B: Float Valve
C: Air Vent
D: Float Chamber

Disassembly, Cleaning, and Reassembly Precautions

are the instructions for removing and reinstalling the link rod
• Here
and the linkage spring that connect the carburetor to the governor

•
•

arm: With the carburetor mounted on the engine, insert a flat-blade
screwdriver between the throttle lever at the carburetor and the link
rod, and gently twist the screwdriver to pry up on the link rod, thus
removing the link rod from the hole in the throttle lever. To reinstall
the link rod, use your fingers to press the link rod into the hole. Use
a pair of pliers or a flat-blade screwdriver to remove and reinstall the
linkage spring.
During disassembly, carefully note the orientation (top, bottom, right,
left, etc.) of the gaskets so that they can be replaced correctly during
reassembly. All gaskets must be replaced with new ones.
Use a solvent with a high flash point to wash the carburetor and make
sure to prevent contamination by foreign matter.

CAUTION
Gasoline is extremely dangerous due to its high volatility. Handle it away from sparks or fire and ensure proper ventilation.

NOTE
Do not use a solvent with rubber or plastic parts.
carburetor cleaner into the internal holes in the carburetor to
• Spray
ensure their opening. Then, wash the carburetor in hot water, allow
it to dry naturally, and blow clean compressed air through the holes
if necessary.

3-4 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Carburetor
how the float valve spring is fitted. Make sure that the first coil
• Check
of the float valve spring is completely wrapped in both spring grooves
that are provided at the two ear-shaped protrusions on the float valve
body.

NOTE
Do not unnecessarily disassemble the float valve spring because
this could damage the valve spring.

CAUTION
Do not use large tools to apply excessive force in order to
tighten the screws. Make sure to use a tool that is appropriate
for the respective part and carefully tighten the screws.
screws used for retaining the throttle valve and the choke valve
• The
are crimped at their threaded ends to prevent them from loosening.
Therefore, do not disassemble them unnecessarily.
A: Spring
B: Float Valve
C: Ear-Shaped Protrusion
D: Spring Groove

Adjustment
Ordinarily, it is not necessary to adjust the carburetor because it is
adjusted at the factory to an optimal fuel setting. However, if the engine
runs poorly, follow the procedures given below to adjust the carburetor.
Pilot Screw Adjustment
Slowly turn the pilot screw in the clockwise direction until a slight
resistance is felt.
Then, back out the pilot screw two turns counterclockwise (for
tentative setting).
Install the air cleaner in the normal manner and warm up the engine
by operating it without a load.
Set the speed adjustment lever to the low-speed (idling) position.
Keep the throttle lever on the carburetor pushed gently to the fully
closed position, and turn the idle adjustment screw so that the engine
attains the idle speed.
Keep the throttle lever pushed to the fully closed position, and turn
the pilot screw in and out to find the position in which the idle speed
of the engine is at the highest rpm. From that position, back out the
pilot screw one-quarter of a turn in the counterclockwise direction.
This completes the pilot screw adjustment.
A: Pilot Screw
B: Throttle Lever
C: Idle Adjustment Screw
D: Low-Speed Set Screw
E: Hight-Speed Set Screw
F: Governor Arm
G: Pivot Arm
H: Governor Spring
I: Governor Arm
J: Pivot Arm
K: Snap Pin

•
•
•
•
•
•

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-5
Carburetor
Minimum No-Load Speed Adjustment
After completing the pilot screw adjustment, the minimum no-load
adjustment must be adjusted.
Keep the throttle lever on the carburetor pushed gently to the fully
closed position, and turn the idle adjustment screw so that the engine
runs at 100 rpm lower than the set idle speed. (This is called the
"carburetor’s idle speed setting".)
Release the throttle lever of the carburetor to free the speed
adjustment lever. Turn the low-speed set screw on the control panel
to set the engine speed to the minimum no-load speed.

•
•
•

Minimum No-Load Speed (idling) Setting (crankshaft speed)
FE120, 170:
1600 rpm
FE250, 290, 350, 400:
1300 rpm

NOTE
If the minimum no-load speed is specified for a particular piece of
equipment, follow that specification.
Maximum No-Load Speed Adjustment
After completing the minimum no-load speed, it is necessary to adjust
the maximum no-load speed.
Keep the speed adjustment lever to the high-speed side, and turn the
high-speed set screw on the control panel to set the engine speed
to the specified maximum no-load speed. (If the maximum no-load
speed is specified for a particular piece of equipment, follow that
specification.)

•
•

Maximum No-Load Speed Setting
4000 rpm (crankshaft)

NOTE
All adjustments described in steps "1." through "3." must be
performed on a warm engine and do not change their adjustment
sequence.
A:
B:
C:
D:
E:
F:
G:

Pilot Screw
Throttle Lever
Idle Adjustment Screw
High-Speed Set Screw
Low-Speed Set Screw
Governor Arm
Pivot Arm

3-6 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Carburetor
Carburetor with Fuel Cutoff Valve
To prevent after-burns that occur in the form of combustion in the
muffler when the engine is stopped, the float chamber of this carburetor
is provided with a solenoid-actuated fuel cutoff valve.
When the engine switch is turned to the STOP position, the solenoid
operates the fuel shut off solenoid valve to stop the flow of the fuel that
is supplied to the main jet.
When the engine switch is turned to the START or RUN position, the
fuel shut off solenoid valve opens automatically to supply the fuel.

•
•
•

Inspect the fuel shut off solenoid valve as follows:
Remove the fuel shut off solenoid valve by turning it counterclockwise.
Keep the tip of the fuel shut off solenoid valve pushed 1 to 2 mm,
and connect 12 V DC current as shown in the diagram.
If the fuel shut off solenoid valve does not retract when the power is
connected, the solenoid is defective. In this case, the fuel shut off
solenoid valve must be replaced.

NOTE
To enable the shut off solenoid valve to retract, the tip of the shut
off solenoid valve must be pushed slightly.
A: Shut off Solenoid Valve
B: Solenoid
A wiring diagram for the carburetor with a fuel shut off solenoid valve
is shown on the right.
A: Engine
B: Spark Plug
C: Ignition Coil
D: ACD
E: Igniter (separate type)
F: Carburetor
G: Fuel Shut off Solenoid Valve
H: Key Switch
I: Regulator
J: Fuse
K: Battery
M: Starter Motor

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-7
Governor Mechanism
Governor Operating Mechanism
Connected to the throttle lever on the carburetor via a link rod, the
governor operates automatically in accordance with load fluctuations in
order to maintain a constant engine speed.
The governor relies on centrifugal force for its operation. When the
engine speed increases, the governor weight (which is attached to the
governor gear that is meshed to the crankshaft gear) opens outward
by centrifugal force. This movement pushes the sleeve outward, which
moves the governor lever in the direction to close the throttle valve.
Conversely, when the engine speed decreases, the governor lever
moves in the direction to open the throttle valve.
Ordinarily, fluctuations in the load that is applied to the engine
also cause the engine speed to fluctuate. When the load decreases
suddenly, the engine speed increases momentarily, but because the
governor weight moves the throttle valve in the closing direction, the
engine speed is kept constant. When the load increases suddenly, the
engine speed decreases momentarily, but because the governor arm
is retracted by the governor spring, the throttle moves in the opening
direction to keep the engine speed constant.
A: Throttle Lever
B: Carburetor
C: Governor Weight
D: Sleeve
E: Camshaft
F: Crankshaft
G: Governor Shaft
H: Governor Arm
I: Throttle Valve
J: Link Rod
K: Governor Spring

3-8 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Governor Mechanism
Governor Gear Assembly Installation
CAUTION
Do not remove the governor gear assembly unless the parts
are to be replaced. The parts cannot be reused once they are
removed.
two screwdrivers of an appropriate size to remove the governor
• Use
gear assembly. Protect the surface of the gasket on the crankcase

•

cover to prevent it from becoming damaged during the removal of the
governor gear assembly.
Install the sleeve on the governor gear assembly before the installation of the governor gear assembly.

NOTE
The sleeve cannot be installed after the governor gear assembly
has been installed.
install, first place the thrust washer over the shaft. Then, install
• To
the governor gear assembly (with the sleeve attached) on the shaft
so that step [E] is fitted securely in groove [F].

installing the assembly, gently turn the governor by hand to make
• After
sure that the governor weight and the sleeve move smoothly.
A:
B:
C:
D:
E:
F:

Sleeve
Governor Gear Assemblly
Thrust Washer
Shaft
Step
Groove

Governor Arm Installation (Setting the Governor)

the throttle linkage and the spring on the governor arm.
• Install
Install
governor arm on the governor shaft and hand-tighten the
• clamp the
nut.
the clamp nut, and turn the end of the governor arm all
• Loosen
the way in the direction indicated below to keep the throttle valve
fully open. Meanwhile, insert the pin into the hole at the end of the
governor shaft, turn the end of the governor shaft all the way in the
direction indicated below, and tighten the clamp nut.
Direction of Rotation for Tightening the Governor Arm
and the Governor Shaft
FE120, 170:
Clockwise
FE250, 290, 350, 400:
Counterclockwise

1.
2.
3.
4.
5.
6.
7.
8.

Governor Shaft
Pin
Idling Posirion
Clockwise
Clip
End Hole
Governor Arm
Calmp Nut

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-9
Governor Mechanism
A:
B:
C:
D:
E:

Governor Arm
Throttle Valve
Governor Shaft
Clamp Nut
Pin

3-10 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Air Cleaner
The quality of the inspection or maintenance of the air cleaner
significantly affects the durability and the performance of the engine.
If the engine is used in a dusty area, the air cleaner element should be
cleaned more frequently than the regular inspection intervals.

Element Cleaning

sponge element should be used slightly wet with oil. To clean
• The
the sponge element, first wash it thoroughly in cold or warm water

•

that contains detergent. Then, rinse it in plain water and allow it to
dry. Immerse the element in fresh engine oil, wrap it in a clean cloth,
squeeze the oil out of it, and install the element while it retains some
oil.
To clean the paper element, gently tap on the steel end plate of the
element to remove the dust. Otherwise, wash it in a soap solution by
shaking it, rinse it in water, and allow it to air dry. If the element is
extremely dirty, replace it with a new one.
Type A: for FE120, 170
Type B: for FE250, 290, 350, 400
1. Sponge Element
2. Paper Element

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-11
Cooling System
All the cooling fans of the FE series engines are the separate type
that can be separated from the flywheel.
FE290 type:

NOTE
On the engine produced before May 1996, the flywheel and the
cooling fan are integrated and cannot be disassembled.
separate type cooling fan can be assembled by aligning the concave
• Aportions
along the circumference of the fan with the magnets on the

•
•

flywheel.
Clean the cooling fan blades if they have debris or dust on them.
If the fan blades are damaged, replace the cooling fan with a new
one.
A: Convex Area of Cooling Fan
B: Mgnet Portion
C: FE120D-AB00 only

3-12 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Fuel Tank and Filter
an appropriate container under the fuel filter to catch the fuel.
• Place
Remove the filter pot, turn the fuel tap ON, and completely drain the
fuel from the fuel tank and the fuel line.
If the drained fuel contains dust or water, the fuel line from the fuel
filter to the carburetor must be inspected and cleaned.

CAUTION
Gasoline is extremely dangerous due to its high volatility. Handle it away from sparks or fire and ensure proper ventilation.
the fuel tank is deformed, cracked, or rusted, replace it with a new
• Ifone.
draining the fuel from the tank, pour a cleaning solvent into the
• After
tank and shake it well. Discard dust and sediments together with the

•
•
•
•

cleaning solvent.
Using compressed air, thoroughly dry the inside of the fuel tank and
the fuel filter before installing them.
Make sure that the fuel gauge operates smoothly, and replace it with
a new one if it is defective.
Inspect the breather hole in the tank cap and the air passage to make
sure that they are not plugged.
Remove retaining screw [8] on the inside of the tank cap and remove
spring plate [7].

NOTE
Retaining screw [8] is a tapping screw, so make sure not to crush
the threads. It is best not to overtighten the screw.
1.
2.
3.
4.
5.
6.
7.
8.

Fuel Tank
Fuel Filter (fuel tap)
Filter Pot
Tank Cap
Fuel Gauge
Filter (strainer)
Spring Plate
Retaining Screw

adhesive tape to cover hole [A] from which the screw was
• Use
removed. Place your mouth on air hole [B] to blow air into it and
verify that air comes out with great force from air passage [C].
If air does not come out of the air passage or if it is weak, replace
the tank cap with a new one.
A: Thread Hole
B: Air Hole
C: Air Passage

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-13
Ignition System
Description of Function
The ignition mechanism is the transistorized type and consists of the
following parts:
Ignition Coil
Igniter
Flywheel (with permanent magnet)
These components do not contain mechanical contact parts and do
not require regular inspection.
Electronic Ignition Device

revolution of the flywheel generates voltage between terminals
• The
[A] and [B], causing base current IB1 to flow from TR1. Then, current
IC1 that is amplified by TR1 flows to form the primary circuit.

flywheel revolves further and the voltage that is generated
• The
between terminals [A] and [B] increases. When the flywheel reaches
the position of the ignition timing, signal base current IB2 flows from
automatic ignition advance circuit C to transistor TR2. At that instant,
the current changes into collector current IC2, which is amplified by
transistor TR2.
In the meantime, because the internal resistance of TR2 is considerably lower than TR1, IB1 that was flowing through TR1 until then will
turn into IC2, thus changing its direction to flow via TR2.
In this manner, base current IB1 of TR1 will not momentarily flow,
thus causing large current IC1 that was flowing between terminals
[A] and [B] until then to stop suddenly.
Due to the sudden change in the current in the primary circuit, a high
voltage is generated in secondary side [F], causing spark plug [G] to
spark.
A, B: Igniter Terminal
C: Automatic Ignition Advance Circuit
E: Primary Coil
F: Secondary Coil
G: Spark Plug
ESW: Engine Switch

•
•
•

3-14 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Ignition System
Automatic Ignition Advance Device
This device enables the engine to achieve appropriate ignition timing
in all speed ranges. The ignition timing must be retarded slightly when
the engine is started and at the low- to medium-speed range. On the
other hand, the ignition timing must be advanced in the high-speed
range in order to generate the sparks early on, because the intervals of
the air-fuel mixture ignition and expansion are shorter.
The diagram on the right shows the relationship between the
crankshaft speed and the ignition timing (degrees before the top dead
center) of the automatic ignition timing device of the FE series.

Spark Inspection

•

Check for sparks as follows:
Remove the spark plug, connect it to the plug cap that is attached
to the high-tension lead, and place the spark plug in contact with the
engine block. When doing so, place the spark plug as far away as
possible from the spark plug hole and make contact at an area that
does not contain gasoline.

CAUTION
Perform the spark inspection after making sure that there is no
presence of gasoline in the area in order to prevent unintended
ignition.
the stop switch or the key switch ON to turn the crankshaft, and
• Turn
check if sparks are generated at the electrode of the spark plug.
If there are no sparks or the sparks are weak, clean the spark plug,
adjust the spark plug electrode gap to between 0.7 and 0.8 mm, and
check for sparks again.
If there are no sparks or the sparks are weak even after cleaning the
spark plug and adjusting its electrode gap, replace the spark plug
with a new one and check for sparks again.
If there are no sparks or the sparks are weak even after installing a
new spark plug, inspect the ignition system.

Spark Plug Cleaning and Inspection

a wire brush, remove the carbon deposits from the spark plug.
• Using
If the spark plug is contaminated with oil, wash it in a cleaning solvent.
the electrode is worn or the insulator is cracked, replace the spark
• Ifplug.
a gap gauge, measure the electrode gap of the spark plug.
• Using
If the gap is incorrect, adjust it to the correct gap by bending the
horizontal electrode.
Spark Plug Electrode Gap
Standard:
0.7 ~ 0.8 mm (0.030 ~ 0.032 in)

• Tighten the spark plug to the specified torque.
Ignition Plug Specification Tightening Torque
23 N1m (2.3 kg1m, 17 ft1lb)

A:
B:
C:
D:

Center Electrode
Horizontal Electrode
Insulator
Electrode Gap

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-15
Ignition System
Ignition Coil Inspection
Spark Characteristics Measurement
Connect the ignition coil to a coil tester to measure its spark
characteristics. Follow the measurement instructions provided by
the tester manufacturer for the proper measurement procedure. (For
testing purposes, remove the plug cap from the ignition coil.)

•

Ignition Coil Spark Characteristics (three-wire spark gap)
Standard:
7 mm (0.28 in) minimum

If the spark characteristics are below the standard, the ignition coil
is defective. If the spark characteristics are normal, the plug cap is
defective.

Ignition Coil Resistance Measurement
If a coil tester is unavailable, use a hand tester (P/N 57001-1394)
to measure the internal resistance of the coil. Although this test is not
sufficient to determine the integrity of the coil, it will serve as a criterion
for making a judgment.
Connect the hand tester as shown in the diagram on the right, set
it to the measurement ranges listed in the table below, and measure
the resistance values. 2 Ignition Coil Internal Resistance (separate
igniter type)

•

Ignition Coil Internal Resistance (separate igniter type)
Measurement Area
Primary Coil
Secondary Coil

( )

Measurement Range

21
21k

Resistance

R
R

0.6 ~ 1.10
6.0 ~ 10.0 k

Ignition Coil Internal Resistance (integrated igniter type)
Measurement Area
Primary Coil
Secondary Coil

Measurement Range

21
21k

R
R

( )
Resistance
0.6 ~ 1.4

6.0 ~ 11.0 k

If the measured value is within the range given above or greater, the
coil is normal. If the measured value is lower than the above, the coil
is defective and it must be replaced with a good one.
1. Measurement of Primary Coil Resistance
2. Measurement of Secondary Coil Resistance
3. Ignition Coil

3-16 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Ignition System
Igniter Inspection
Measure the internal resistance of the igniter.
Individual Igniter Inspection
To test the individual igniter shown in the diagram on the right, set the
measurement range of the hand tester to R 2 100 and measure
the resistance.

•

Individual Igniter Resistance

(k )

Tester negative (–)

Tester positive (+) terminal

Terminal

Case (A)

Terminal (B)

Case (A)

–––

0.1 ~ 1.0

Terminal (B)

1 ~ 10

–––

If the measured value differs from the above, replace the igniter.
Igniter (with Oil Warning Light) Measurement
Set the measurement range of the hand tester to R 2 100 in order
to measure the resistance at the areas given in the table below.

•

Igniter (with Oil Warning Light) Resistance
Tester Negative (–)
Terminal

(k )

Tester Positive (+) Terminal
D (brown)

C (black)

E (yellow)

D (brown)

–––

0.1 ~ 1.0

1 ~ 10

C (black)

1 ~ 10

–––

5 ~ 20

E (yellow)

10 ~ ∞

–––

If the measured value differs from the table above, replace the igniter.
To inspect the oil warning light (LED), refer to the section on the
lubrication system.
A: Igniter
B: Oil Warning Light
C: Primary Terminal
D: Ground Terminal
E: Oil Level Sensor Terminal
CDI Igniter Measurement
Set the measurement range of the hand tester to Rx100 in order to
measure the resistance at the areas given in the table below.
If the measured value differs from the table above, the igniter is
defective and it must be replaced.

•

CDI Igniter Resistance

( )

Tester
Negative (–)
Terminal

Black (switch)

Red (exciter)

Light Green/
Red (pulser)

Grey (ground)

Black/Yellow
(ignition)

Black (switch)

–––

10 ~ ∞

Red (exciter)

200 ~ 2 k

–––

10 ~ ∞

Light Green/
Red (pulser)

10 ~ ∞

–––

10 ~ ∞

Grey (ground)

1 k ~ 10 k

200 k ~2 k

10 ~ ∞

–––

10 ~ ∞

Black/Yellow
(ignition)

10 ~ ∞

–––

Tester Positive (+) Terminal

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-17
Ignition System
Controller (with Warning Light) Measurement
Set the measurement range of the hand tester to R 2 1 k
measure the resistance at the areas given in the table below.

•

and

Controller (without ground) Resistance

(k )

Tester (–) Negative

Tester Positive (+) Terminal

Terminal

C (black)

D (black/yellow)

C (black)

–––

50 ~∞

D (black/yellow)

1 ~7

–––

Controller (with ground) Resistance
Tester (–) Negative

(k )
Tester Positive (+) Terminal

Terminal

C (black)

D (black/yellow)

E (brown)

C (black)

–––

50 ~ ∞

D (black/yellow)

1~7

–––

50 ~ ∞

E (brown)

50 ~ ∞

–––

If the measured value differs from the table above, replace the
controller.
To inspect the oil warning light (LED), refer to the section on the
lubrication system.
A: Igniter
B: Oil Warning Light
C: Primary Terminal
D: Oil Level Sensor Terminal
E: Ground Terminal

Flywheel Disassembly and Reassembly

a strap wrench, hold the flywheel and remove the flywheel
• Using
retaining nut.
flywheel puller to remove the flywheel.
• UseA: aStrap
Wrench

NOTE
If an appropriate flywheel puller is unavailable, position the flywheel
nut flush with the crankshaft end, and strike it with a mallet to
remove the flywheel.
reassembly, wipe the flywheel and the tapered portion of the
• Before
crankshaft to remove any dust or oil.
sure that the woodruff key is installed correctly in the groove of
• Make
the crankshaft, install the flywheel, and install the retaining nut.
a strap wrench, hold the flywheel, and tighten the flywheel nut
• Using
to the specified torque. (Refer to the Tightening Torque Specifications
table.)
A: Flywheel Nut

3-18 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Ignition System
Ignition Coil Reassembly (Air Gap Adjustment)

the flywheel so that the magnet on the flywheel is on the
• Rotate
opposite side of the area in which the ignition coil is to be installed.
two bolts to hand-tighten the ignition coil to the area in which the
• Use
coil is to be installed, and slide a 0.3 mm gap gauge between the foot

•

of the coil and the periphery of the flywheel.
Keep the ignition coil pressed towards the flywheel and evenly tighten
the coil retaining bolts to the specified torque.
Ignition Coil Air Gap
Standard:
Adjustable Range:

0.3 mm (0.012 in)
0.25 ~ 0.4 mm (0.010 ~ 0.016 in)

Ignition Coil Retaining Bolt Specified Tightening Torque
FE120 (M6 bolt):
6.0 N1m (0.6 kg1m, 53 in1lb)
FE170, 250, 290, 350, 400:
3.5 N1m (0.35 kg1m, 31 in1lb)

A:
B:
C:
D:

Magnet
Coil Foot
Coil Retaining Botls
Gap Gauge

Key Switch (engine switch) Inspection

the measurement range of the hand tester to Rx1 and check
• Set
whether the lead from the key switch exhibits the continuity indicated
in the table on the right.
If the leads exhibit the continuity indicated in the table on the right,
the key switch is good.

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-19
Charging System
The state of charge of the battery must be determined by measuring
the terminal voltage of the individual battery.
Individual Battery’s Terminal Voltage
Standard:
12 V

If the terminal voltage is below the standard, the battery must be
recharged.

Charging System Inspection

•
•

Fully recharge the battery before inspecting the charging system.
Warm up the engine.
Connect a voltmeter to the battery terminals to measure the voltage.
When the engine speed is low, the voltmeter reads the battery voltage.
The voltage increases with an increase in the engine speed, although
the voltage fluctuation range will be within the specified values.
If the output voltage is higher than the specified value, the rectifier is
damaged or the lead is disconnected.
If the output voltage does not increase with an increase in the engine
speed, the rectifier is damaged or the alternator output is insufficient
for the applied load.
Rectifier Output Specified Voltage
Specified Value:
Battery Voltage ~ 15 V

ACG Inspection

the connectors from the alternator, connect a hand tester
• Disconnect
to the lead of the charging coil and the ground in order to measure
the internal resistance of the charging coil.
ACG Internal Resistance
Coil Type

Specified Range ( )

12 V – 2 A

0.40 ~ 0.67

12 V – 4 A

0.82 ~ 1.38

12 V – 13 A

0.26 ~ 0.44

If the measured value is out of the specified range, replace the
charging coil.
If the resistance of the coil is normal but there is no voltage, the rotor’s
magnetic force has diminished, so the rotor must be replaced.
A: ACG Lead (green/white)
B: Ground

Rectifier Inspection

the resistance measurement range of the hand tester to R 2 1
• Set
k .
the resistance between the male and female connectors in
• Measure
both positive and negative directions.
If the measured values are lower in one direction, and the other
direction is ∞, the rectifier is normal. The lower value should generally
be between 0 and the halfway point of the scale, although this could
vary from tester to tester.
If the measured value differs from the above, the rectifier is defective,
so it must be replaced with a good one.
1. Rectifier
2. Male Connector
3. Female Connector

3-20 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Charging System
Regulator Inspection

the connector from the regulator.
• Disconnect
Set
the
measurement
of the hand tester to R 2 1 k and
• measure the resistancerange
at the areas given in the table below.
this test is not sufficient to determine the integrity of the
• Although
regulator, it will serve as a criterion for making a judgment.
Regulator Internal Resistance
Tester
Negative
(–)
Terminal

(k )
Tester Positive (+) Terminal

–

---

∞

4 ~ 20

---

0.2 ~ 1

1~5

200 ~ ∞

–

3 ~ 15

0.2 ~ 1

---

1~5

200 ~ ∞

1~5

∞

---

∞

1~5

∞

---

∞

10 ~ 50

1~5

1.5 ~ 7.5

4 ~ 20

---

If the measured resistance differs from the table above, replace the
regulator.
A: Key Switch
B: Charging Indicator Light

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-21
Starter System
Starter Motor Construction
An FE series engine comes with a Bendix type or shift-lever type
starter motor.
The electrical circuit of a starter motor consists of a key switch (engine
switch), solenoid (or solenoid switch on the Bendix type), battery, and
starter motor.
A: Starter Motor
B: Key Switch
C: Battery
D: Solenoind

With the shift lever type, turning the key switch to the START position
causes a small amount of current to flow to the solenoid, which actuates
the plunger, which in turn moves the shift lever in order to engage the
pinion gear of the starter motor with the ring gear of the flywheel. At the
same time, a large amount of driving current flows to rotate the motor,
which transmits the rotational movement to the crankshaft.
With the Bendix type, turning the key switch to the START position
causes a small amount of current to flow to the solenoid switch, thus
causing the solenoid to actuate and the solenoid switch to close. This
causes a large current to flow to the starter motor, enabling the starter
motor to start rotating. When the starter motor starts rotating, the pinion
moves by inertia to the ring gear (outer side) along the free-sliding
threads that are cut on the armature’s outer periphery and on the inside
of the pinion gear. As the pinion gear meshes with the ring gear in this
manner, the rotational movement of the starter motor is transmitted to
the crankshaft.
When the engine starts and the key switch is turned to the ON (run)
position, the current to the solenoid is cut off, causing the plunger and
the solenoid switch to return to their original positions. On the shift
lever type, the pinion gear separates from the ring gear and returns to
its original position, simultaneously with the return of the plunger. On
the Bendix type, the inertia of the ring gear causes the pinion gear
to return to the starter (inner side) along the free-sliding threads, thus
returning to its original position.

CAUTION
Do not operate the starter motor continuously for more than
5 seconds. Turn OFF the switch after 5 seconds, then allow
approximately 15 seconds to elapse before operating the
starter again.
Operating the starter for a long time could drain the battery
and burn the starter motor.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.

Nut
Nut
Solenoid
Bolt
Rear Cover
Insulator
Brush Holder
Brush Spring
Brush
Yoke Assembly
Shift Lever
Armature
Washer
Stopper
Snap Ring
Clutch Assembly
Front Cover

3-22 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Starter System
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

Snap Ring
Collar
Spring
Clutch Assembly
Nut
Spring Washer
Bolt
Rear Cover
Washer
Brush Holder
Brush Spring
Brush
Yoke Assembly
Armature
Washer
Front Cover

Solenoid (Starter Motor) Wiring Inspection
Although the following procedure gives the steps for inspecting the
shift-lever type starter motor, it can also be applied to the Bendix type
by replacing the word "solenoid" with "solenoid switch".

NOTE
First check the battery and make sure that it is fully charged.

•

Detach lead [A] from the solenoid terminal of the starter motor, and
keep it away from the solenoid terminal.

lead [B] that connects the key switch to the solenoid, set the
• Detach
measurement range of the tester to DC25 V, and connect it to lead [B]
and a ground on the unit. Turn the key switch to the START position
and read the voltage on the tester.
If the voltage is 0 or lower than the battery voltage, inspect the key
switch and the wiring. (Refer to the switch section of the Ignition
System.)
If the voltage is the same as the battery voltage, it is normal.

the measurement range of the tester to Rx1 , and read the
• Set
resistance between terminal [C] and a ground on the unit.
The solenoid is normal if the resistance is approximately 0
not, replace the solenoid.

. If it is

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-23
Starter System
lead [B] to terminal [C]. Set the measurement range of the
• Connect
tester to R 2 1 , and connect it to the two terminals on the solenoid.
Turn the key switch to the START position to read the tester.
If the solenoid clicks once, the tester reads 0 , and the pinion gear
advances forward, the solenoid and the wiring are normal.
If the solenoid does not make a clicking sound, and the reading on
the tester is greater than 0 , the solenoid is defective and it must be
replaced.
If the solenoid clicks once and the reading on the tester is greater
than 0 , the solenoid is defective and it must be replaced.

Starter Motor Inspection
CAUTION
Make sure that there are no flammable substances in the work
area. Always keep the pinion gear of the starter motor away
from your body.

• Disconnect the leads at the battery before removing the starter motor.
NOTE
First disconnect the negative [-] lead of the battery, followed by the
positive [+] lead, to prevent sparks from being created during the
operation.
the starter motor from the engine.
• Remove
• Secure the starter motor on a vise.

NOTE
Be careful not to deform the starter motor when securing the starter
motor on a vise.
the positive [+] lead of the battery to terminal [D] of the
• Connect
solenoid.
place the negative [-] lead of the battery in contact with
• Momentarily
a non-painted area of the starter motor body.
If the pinion gear does not spin, repair or replace the starter motor.

Brush Overall Length Measurement
Measure the overall length of the brushes.
If the brushes are shorter than their service limit, replace them with
new ones.
Brush Overall Length Service Limit (minimum)
Sift Lever Type:

P/N 21163-2089, 2095

6.0 mm (0.24 in)

Bendix Type:

P/N 21163-2108

3.5 mm (0.14 in)

Bendix Type:

P/N 21163-2096

8.5 mm (0.33 in)

3-24 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Starter System
Commutator Diameter Measurement
Measure the diameter of the commutator at several areas.
If the diameter is smaller than the service limit, replace the armature.
Commutator Diameter Service Limit (minimum)
Sift Lever Type:

P/N 21163-2089, 2095

27 mm (1.06 in)

Bendix Type:

P/N 21163-2108

23 mm (0.91 in)

Bendix Type:

P/N 21163-2096

27 mm (1.06 in)

Commutator Groove Depth
Measure the depth of the grooves between the segments of the
commutator.
If the groove depth is smaller than the service limit, use a thin file or
a piece of steel to file the insulation portion to the standard depth.
Commutator Groove Depth
Standard:
0.5 ~ 0.8 mm (0.020 ~ 0.032 in)
Service Limit: 0.2 mm (0.008 in)

A: Segment
B: Insulation Portion
C: Groove Depth

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-25
Recoil Starter
CAUTION
The recoil spring is stored in the reel under high tension. Hold
it firmly when handling so that the spring does not jump out.

Disassembly

the rope out approximately 350 mm, and tentatively tie a knot at
• Pull
that position.
out the knot of the rope that is pushed into the recess in the
• Pull
handle, undo the knot, and remove the handle.
holding the reel with your hand, undo the knot of the rope, and
• While
pull the rope out through the hole in the case. Hook the rope on the

•
•
•

cutout of the reel, and slowly allow the reel to retract in a direction
that will relieve the tension of the coil spring.
Remove the retaining screw from the center of the reel, and remove
the parts while making sure not to allow the recoil spring to jump out.
To remove the recoil spring, make sure that the tension of the spring
has been completely relieved. Then, remove the reel by carefully
pulling the reel straight up. The recoil spring remains retracted in the
reel or spring case.
During the removal of the recoil spring, carefully separate it from the
reel, while retracting it outward from the center of the spring.

NOTE
On the FE120, 170, 250, 290, 350, and 400 also, handle the recoil
spring carefully to prevent it from jumping out, and do not reverse
the winding direction of the recoil spring and the rope.
T1:
T2:
G:
L:

Tightening Torque 10 N1m (1.0 kg1m, 7.2 ft1lb)
Tightening Torque 6 N1m (0.6 kg1m, 4.3 ft1lb)
Apply grease.
Apply non-coagulating thread lock

Reassembly

not reverse the direction of the coil spring during reassembly. Ap• Do
ply grease to the recoil spring and the case shaft before reassembly.
the reel to the case so that the inner hook of the recoil spring
• Attach
engages securely with the case hook.
the tab, tab spring, and guide plate in their original
• Assemble
positions. Apply a non-coagulating type thread lock on the threaded
portion of the retaining screw and tighten the screw.

apply an initial load to the recoil spring, rotate the reel two turns in
• To
a direction that compresses the recoil spring. Hold the reel, pass the

•
•

end of the rope through the hole in the case, and make a tentative
knot.
Insert the end of the rope into the handle, make the final knot there,
and undo the tentative knot.
Pull on the rope and make sure that the tab operates normally.
A: Recoil Spring Inner Hook
B: Case Hook
C: Case Shaft

3-26 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Cylinder Head
Compression Inspection

warming up the engine, stop the engine. Remove the spark
• After
plug and connect a compression gauge to the spark plug hole.

NOTE
Connect the spark plug cap to the removed spark plug and ground
the spark plug against the engine body. Make sure that there are
no flammable substances in the surrounding area.
If the engine is equipped with an electric starter, make sure that
the battery is fully charged.
open the engine throttle and the choke valve. Operate the recoil
• Fully
starter or electric starter and read the maximum compression.
Compression (minimum)
with Recoil Starter:
with Electric Starter:

290 kPa (3 kg/cm2, 42 psi)
390 kPa (4 kg/cm2, 57 psi)

If the compression reading is lower than the minimum value given
above, refer to the Troubleshooting section in order to repair the
engine.
A: Installing the compression gauge

Disassembly

the retaining bolts from the rocker cover and remove the
• Remove
rocker cover together with the breather pipe.
the rocker arm.
• Remove
Bring the piston to the top-dead-center of the compression stroke.

•

This will allow the rocker arm to move freely (except FE350 and 400).
On the FE120, 170, and 250, loosen the lock nut on the rocker arm
pivot to remove the lock nut and the rocker arm pivot. Then, remove
the rocker arm.
On the FE290, 350, and 400, remove the E-ring, push the rocker shaft
towards the exhaust side, and remove the washer and the rocker arm.
Remove the pushrods.

NOTE
Mark the pushrods to prevent the intake and exhaust positions from
becoming interchanged during reassembly. This is not necessary
on the FE350 and 400.
1. Rocker Arm Pivot
2. Lock Nut
3. Pushrod
the cylinder head retaining bolts little by little, evenly in the
• Loosen
reverse order of tightening, to remove the cylinder head.

CAUTION
The cylinder head could become warped if the head bolts are
not loosened evenly.
To ensure the proper loosening sequence, refer to the tightening
sequence on the next page.
A: E-ring
B: Rocker Shaft
C: Rocker Arm
D: Washer

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-27
Cylinder Head
Cleaning and Inspection

the cylinder head for the presence of any cracks or missing
• Inspect
fins. Replace the cylinder head if any of those conditions exist.
the carbon deposits off the combustion chamber and the
• Clean
exhaust port, and wash the cylinder head in a cleaning solvent.
a straightedge against the combustion chamber side of the
• Place
cylinder head and use a gap gauge to inspect for warpage.
If the warpage exceeds the service limit, replace the cylinder head.
Cylinder Head Warpage (maximum)
Service Limit: 0.05 mm (0.002 in)

the breather
• Inspect
Lubrication System.)

valve.

(Refer to the breather section in

A: Straightedge
B: Gap Gauge

Reassembly
CAUTION
Make sure that the piston is in the top-dead-center of the
compression stroke.
the mating surfaces of the cylinder and the cylinder head, and
• Clean
replace the gasket with a new one.
the pushrods in their original positions in the cylinder block and
• Place
install the cylinder head.

•

At this time, make sure that each end of a pushrod is properly fitted
in the recessed area of the tappet and the rocker arm.
Tighten the cylinder head retaining bolts little by little, evenly in
accordance with the tightening sequence given in the diagram on the
right, to their specified torque. (Refer to the section on Tightening
Torque Specifications.)

3-28 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Valve System
Hydraulic Lash Adjuster (HLA)
The FE350 and 400 are equipped with a Hydraulic Lash Adjuster
(HLA) to automatically adjust the valve train to zero clearance through
hydraulic means.
Purpose of the HLA
The HLA hydraulically adjusts the valve train to zero clearance by
automatically absorbing the changes in the clearance that are created
through thermal expansion or wear. The purpose of the HLA is to
eliminate the need to adjust the clearance of the valve train, reduce
the noise generated by the valve train, and stabilize the performance of
the engine.
HLA Position and Oil Supply Path
The HLA needs the pressurized oil from the oil pump. The diagram
shows the position in which the HLA is installed and the oil supply path.

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-29
Valve System
HLA Construction and Operation
When the cam pushes the HLA upward, the oil in the high-pressure
chamber [H] tries to flow back to the oil pool [I] of the plunger [G]
by passing through the passage [M], but because the check ball [E]
closes the passage [M], the oil cannot flow back and it causes the
hydraulic pressure in the high-pressure chamber [H] to rise.
The oil of the high-pressure chamber [H] in which the hydraulic
pressure has risen leaks little by little through the gap (leak-down
rand) between the plunger [G] and the HLA body [D]. As a result, the
HLA shrinks slightly and pushes the pushrod [P] upward.
When the rotation of the cam causes the HLA to descend to the cam
base circle, the pressurized oil from the oil pump passes through the
oil hole [C] in the HLA body [D], travels through the oil groove [N] that
is cut into the socket [F], and enters the oil pool [I] in the plunger [G].
After filling the oil pool [I], the oil pushes open the check ball [E], and
flows into the lifter cage [J] and the high-pressure chamber [H], in
order to correct the valve train to achieve zero clearance.
A: Snap Ring
B: Oil Metering Hole
K: Plunger
L: Check Valve Spring
O: Check Valve Seat
P: Pushrod

•
•
•
•

3-30 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Valve System
HLA Removal

CAUTION
Always keep the HLA upright, with the end of the HLA on which
the snap ring is visible facing up (socket "A" faces up). If it is
placed on its side or upside down, the oil that is sealed in the
high-pressure chamber [B] could leak out, disabling the HLA
function.

CAUTION
Do not disassemble the HLA because it is extremely difficult
to replenish the oil that is sealed in it.
sure that the piston is in the top-dead-center of the compression
• Make
stroke.
• Pull the HLA [A] out towards the cylinder head.

HLA Inspection
If the valve train noise does not go away after the engine is started,
it could be due to the following reasons:
Wear at the clearance between the HLA body [D] and the plunger
[G].
Debris wedged in the HLA body between the check ball [E] and the
check valve seat [O].
A drop in the hydraulic pressure of the oil supply path for some reason
(refer to the section on the Lubrication System).

•
•
•

NOTE
If debris becomes wedged in the HLA body between the check
ball [E] and the check valve seat [O], it is structurally unfeasible
to perform a repair. Therefore, it is very important to prevent
contamination when changing the engine oil or repairing the engine.

•
•
•

To inspect the HLA, perform a leak-down test as follows:
Place the HLA with its snap ring facing up on a surface plate and
measure the leak-down dimension.
Using your finger or a rod with a rounded tip, firmly press the socket
[A] down. Measure the extent of the recess of the socket [A], which
is the leak-down dimension.
If the leak-down dimension is greater than the service limit, replace
the HLA with a new one.
HLA Leak-Down Dimension (maximum)
Service Limit: 0.5 mm (0.002 in)

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-31
Valve System
HLA Reassembly
Make sure that the piston is at the top-dead-center of the compression
stroke.

•

CAUTION
Make sure to apply engine oil to all the sliding areas of the
HLA, pushrod, rocker arm, rocker shaft, and valve before
reassembly.
the HLA (with its end on which the snap ring is visible facing
• Insert
up) from the cylinder head side of the engine block.
the tip of the pushrod to the recess in the HLA, and the other
• Mate
end with the recess in the rocker arm, and install the cylinder head.
A:
B:
C:
D:
E:
F:
G:

Pushrod
Rocker Shaft
Rocker Arm
Valve
HLA
Engine Block
Cylinder Head

HLA Operation Precaution
The HLA comes filled with low-viscosity oil.
Once the engine starts, the low-viscosity oil is gradually replaced with
the engine oil.
After an engine that has previously operated is rebuilt, the valve takes
approximately 20 minutes to seat itself. Therefore, start a rebuilt
engine 20 minutes after it has been rebuilt. This prevents the engine
from starting poorly due to a compression leak.
If the engine is restarted after the HLA has been replaced with a new
one, the valve could be noisy, but the noise will go away after the
engine is operated for a while in the medium speed range.

Valve Clearance Inspection and Adjustment
NOTE
Inspect and adjust the valve clearance on a cold engine.

•
•
•

Rotate the crankshaft in the normal direction in order to bring the
piston to the top-dead-center of its compression stroke.
Using a gap gauge, measure the clearance of the intake and exhaust
valves.
If the clearance differs from the specified value, adjust it to the
specified value.
Specified Valve Clearance on Cold Engine
Intake:
0.12 mm (0.005 in)
Exhaust:
0.12 mm (0.005 in)

the lock nut. Turn the rocker arm pivot in or out to attain the
• Loosen
specified clearance. (FE120, 170, 250)
On the FE290, use a pair of pliers to hold the adjustment bolt, and
then loosen the lock nut. Turn the adjustment bolt in or out to attain
the specified clearance.
For FE120, 170, 250
A: Rocker Arm Pivot
B: Rocker Arm
C: Locknut
D: Valve
E: Valve Clearance

3-32 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Valve System
a wrench, secure the rocker arm pivot, and tighten the lock nut
• Using
to the specified torque. (Refer to the section on Tightening Torque
Specifications.)
On the FE290, use a pair of pliers to hold the adjustment bolt, and
tighten the lock nut to the specified torque. (Refer to the section on
Tightening Torque Specifications.)
A: Adjustment Bolt
B: Locknut
C: Gap Gauge

Automatic Compression Release (ACR) Device Inspection
The ACR reduces the compression of the cylinder in order to facilitate
the revolution of the crankshaft during the starting of the engine.
Detach the rocker cover and remove the spark plug.
Check whether the valves have the specified clearance.
Slowly turn the crankshaft in the direction of the engine rotation and
observe the movement of the exhaust valve [A] and the rocker arm
[B].
Immediately after the intake valve has closed, the rocker arm [B]
should push open the exhaust valve [A] to attain a lift that is greater
than the service limit given below. If the exhaust valve does not lift to
that height, the ACR that is provided on the camshaft is faulty. (Refer
to the section on Camshaft Inspection.)

•
•
•

Valve Lift Height Service Limit (minimum) by ACR - for Exhaust
FE120, 170, 250, 290:
0.6 mm (0.024 in)
FE350, 400:
1.0 mm (0.039 in)

Valve Disassembly and Reassembly
For FE120, 170:
Disassembly
Place an appropriate receiving plate on the combustion chamber side
of the cylinder head.
Using your thumbs, push down the spring retainer, slide the retainer
towards the side hole, and remove the retainer.
Remove the spring and the valve.
Reassembly
Verify that the valve seat is making proper contact and that the valve
stem moves smoothly in the guide.
The reassembly is the opposite of the disassembly.
Apply engine oil to the valve stem before reassembling the valve.
A: Spring Retainer
B: Side Hole
C: Sliding Direction

•
•
•
•
•
•

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-33
Valve System
For FE250, 290, 350, 400:
Disassembly
Use a valve spring compressor to compress the valve spring and
remove the collet.
Remove the valve spring compressor.
Remove the retainer, valve spring, and valve.
If the stem seal that is provided on the intake side of the FE290, 350,
or 400 is damaged, replace the stem seal with a new one.

•
•
•
•

NOTE
Do not remove the stem seal unless it is necessary to do so.
Valve Spring Compressor
Collet
Retainer
Valve Spring
Stem Seal
Spring Seat

A:
B:
C:
D:
E:
F:

Reassembly
Verify that the valve seat is making proper contact and that the valve
stem moves smoothly in the guide.
The reassembly is the opposite of the disassembly.
Apply engine oil to the valve guide and the lip of the valve stem seal
before reassembling the valve.

•
•
•

Valve Guide Inspection

• Use a bore micrometer to measure the bore of the valve guide.
Valve Guide Bore Service Limit (maximum)
- for both Intake and Exhaust
FE120:
5.562 mm (0.2190
FE170:
5.562 mm (0.2190
FE250:
6.065 mm (0.2388
FE290, 350, 400:
7.065 mm (0.2782

in)
in)
in)
in)

If the measured value exceeds the service limit, replace the valve
guide with a new one.
A: Bore Micrometer

Valve Inspection

the valve head for the presence of any abnormal deposits or
• Inspect
gas leakage.
a wire brush to remove any deposits from the valve.
• Use
the valve for any depression in its contact surface [A], and
• Inspect
whether the thickness of the valve head [B] is below the service limit.
Valve Head Thickness Service Limit (minimum)
- for both Intake and Exhaust
FE120, 170:
0.5 mm (0.020 in)
FE250, 290, 350, 400:
0.6 mm (0.024 in)

If the valve head is smaller than the service limit given above, replace
the valve with a new one. 4. Inspect the valve stem for the presence
of any gummy deposits, discoloration due to seizure, or corrosion.

NOTE
Gummy deposits are caused by the use of old, deteriorated
gasoline. Instruct the user to use fresh, unleaded gasoline.

3-34 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Valve System

•

Use a wire brush to remove the deposits from the valve stem. If the
valve stem does not move smoothly in the valve guide or the stem
shows abnormal wear, replace the valve with a new one.
Using a micrometer, measure the valve stem diameter in several
places.
If the measured value is smaller than the service limit, replace the
valve with a new one.

Valve Stem Diameter Service Limit (minimum)
Intake Valve
FE120, 170:
5.430 mm (0.2138 in)
FE250:
5.930 mm (0.2335 in)
FE290, 350, 400:
6.930 mm (0.2728 in)

Exhaust Valve
5.415 mm (0.2132 in)
5.915 mm (0.2329 in)
6.915 mm (0.2722 in)

both ends of the valve stem on V blocks [A] as shown in the
• Support
diagram. Place a dial gauge [B] against the center, and gently rotate
the valve stem to measure the bend of the stem (by reading the entire
fluctuation of the dial gauge).
Valve Stem Bend Service Limit (maximum)
– for both Intake and Exhaust
FE120, 170:
0.05 mm (0.0020 in)
FE250, 290, 350, 400:
0.03 mm (0.0012 in)

If the measured value is greater than the service limit, replace the
valve with a new one.

Valve Spring Inspection

the valve spring for the presence of corrosion or cracks, and
• Inspect
replace it with a new one if necessary.
• Using a vernier caliper, measure the free length of the valve spring.
Valve Spring Free Lenght Service Limit (minium)
- for both Intake and Exhaust
FE120, 170:
31.8 mm (1.25 in)
FE250, 290:
32.8 mm (1.29 in)
FE350, 400:
38.1 mm (1.50 in)

If the free length is shorter than the service limit, replace the valve
spring with a new one.

NOTE
During reassembly, beware that the spring pitch is smaller at the
valve seat side of the valve spring on the FE250, 290, 350, and
400. For both intake and exhaust valves.
A: Valve Spring

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-35
Valve System
Valve Seat Inspection and Lapping
A prerequisite for inspecting the valve seat contact is that the valve
guide and the valve stem are normal.
Apply a thin layer of fine lapping compound on the contact surface of
the valve.
Using a lapper [A], lap the valve against the seat by rotating the valve.
Pull out the valve and inspect whether there is an even contact at the
valve seat along its entire circumference. If not, lap the valve and the
valve seat.
Lap 8 to 10 times and inspect the contact each time. Repeat this
process until there is contact along the entire circumference.
After completing the lapping, completely wash off the compound from
all parts and allow the cylinder head to dry.
A: Lapper
1. Valve Seat Contact Width

•
•
•
•
•

Valve Seat Correction
If the contact width of the valve seat is nearing the service limit, or
there are small depressions or wear on the valve seat, correct the valve
seat.

Using a 45 (30 only for the intake on FE350 and 400) valve seat
cutter, apply a light force to smoothly cut the valve seat to create a
concentric circle.

Using a 30 (15 only for the intake on FE350 and 400) valve seat
cutter, make a shallow cut so that the valve seat contact [A] will have
the standard width.

•
•

3-36 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Valve System
Valve Seat Contact Standard Width and Service Limit (minimum)
– for both Intake and Exhaust
Standart
Service Limit
FE120, 170:
0.7 mm (0.028 in)
1.7 mm (0.067 in)
FE250, 290, 350,
0.8 mm (0.031 in)
1.9 mm (0.075 in)

400:
Using a 45 (30 only for the intake on FE350 and 400) valve seat

• cutter, apply a light force to remove the burrs from the seat.
a marker (blue ink) on the valve seat to inspect the contact
• Use
between the valve and the valve seat. The valve and the seat must
•

make contact in the center of the contact surface along the entire
circumference as shown in the diagram.
If the contact width is inadequate, cut the seat again and lap the
valve.

Rocker Arm and Rocker Shaft
For FE120, 170, 250
If abnormal wear is present on the ball surface of the rocker arm,
or the surface that comes in contact with the valve stem and the
pushrod, replace the rocker arm with a new one.
For FE290, 350, 400
Using an inside micrometer, measure the bore of the rocker arm
bearing in several places. Because the rocker arm of the FE350
and 400 is made of sheet metal, use a vernier caliper to measure its
bore.
1. Ball surface of rocker arm

•
•

Rocker Arm Bearing Bore Service Limit (maximum)
FE290:
12.074 mm (0.4754 in)
FE350, 400:
12.3 mm (0.4843 in)

•

If the measured value is greater than the service limit, replace the
rocker arm.
Using a micrometer, measure the diameter of the rocker shaft in
several places.
A: Rocker Arm

Rocker Shaft Diameter Service Limit (minimum)
FE290, 350, 400:
11.949 mm (0.4704 in)

If the measured value is smaller than the service limit, replace the
rocker shaft
A: Rocker Shaft

Pushrod Inspection

both ends of the pushrod on V blocks and place a dial gauge
• Support
against the center.
rotate the pushrod to measure its bend through the fluctuation
• Gently
of the dial gauge.
Pushrod Bend - for both Intake and Exhaust
FE290, 170:
0.5 mm (0.020 in)
FE250, 290:
0.3 mm (0.012 in)
FE350, 400:
0.5 mm (0.020 in)

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-37
Piston and Connecting Rod
Disassembly

the engine oil into an appropriate container.
• Drain
Remove
bolts from the crankcase cover. Using a
• wooden orthea retaining
plastic mallet, gently tap on the crankcase cover at

•
•
•
•

the area where the cover is fastened to the crankcase, and remove
the crankcase cover. (Refer to the section on Crankcase Cover
Disassembly.)
Refer to the section on Camshaft Disassembly and remove the
camshaft and the tappet.
* When working on the FE170 that is
equipped with a uniaxial rotation balancer, remove the balancer.
Turn the crankshaft to a position in which the cap bolt [A] is easily
visible.
Remove the two cap bolts and remove the connecting rod cap [B].
Push the big end of the connecting rod towards the cylinder head and
push out the piston and connecting rod assembly.

NOTE
Clean off the carbon from the cylinder bore before pushing out the
piston and connecting rod assembly.
the snap ring from the piston, pull out the piston pin, and
• Remove
take out the piston.
your fingers, open the piston ring [A] at the area where its ends
• Using
meet, and push up the piston ring at the opposite end to remove it
from above the piston.

Reassembly
The reassembly is the opposite of the assembly.
Reassemble the piston rings in the following sequence: lower rail [A1]
spacer [B]
upper rail [A2]
second ring [C]
top ring [D]

•!

NOTE
Install the top ring and the second ring so that their marked side
faces the top of the piston.
of the proper direction of the piston when reassembling the
• Beware
piston with the connecting rod.

NOTE
Apply engine oil to the piston pin holes of the piston and the
connecting rod before assembling them.

3-38 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Piston and Connecting Rod
For FE120, 170, 250, 350, 400
On type D, face the "R" mark on the top of the piston towards the
side of the connecting rod marked "MADE IN JAPAN".
On type G, face the "L" mark on the top of the piston towards the
side of the connecting rod marked "MADE IN JAPAN".
A: Piston
B: Connecting Rod

•
•

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-39
Piston and Connecting Rod
For FE290
On type D, face the arrow on the top of the piston opposite to the
side of the connecting rod marked "MADE IN JAPAN".
On type G, face the arrow on the top of the piston towards the side
of the connecting rod marked "MADE IN JAPAN".
Replace the snap ring for the piston pin with a new one and fit it
securely into the groove of the piston pin hole.

•
•
•

NOTE
Do not reuse an old snap ring. Once a snap ring is removed, it
could be deformed or it could have lost its tension. If it is reused, it
could fall out while the engine is running, and damage the cylinder
wall.
installing the piston and connecting rod assembly into the
• When
cylinder, beware of the direction of the "MADE IN JAPAN" side of
the connecting rod.

NOTE
Apply engine oil to the cylinder bore, crank pin area, connecting
rod big end, and connecting rod bolts before reassembly.
A: Piston
B: Connecting Rod
C: Arrow

For FE120, 170, 250, 350, 400
On both types D and G, the "MADE IN JAPAN" side of the connecting
rod must face the magneto.
For FE290
On both types D and G, the "MADE IN JAPAN" side of the connecting
rod must face the output shaft.

•

the gaps of the piston rings as shown in the diagram, and
• Arrange
use a ring compressor to install the piston from the cylinder head

•

side.
Mate the connecting rod cap to the big end of the connecting rod and
tighten the connecting rod bolts to the specified torque. (Refer to the
section on Tightening Torque Specifications.)

NOTE
After tightening the bolts, make sure that the connecting rod moves
easily in the axial direction along the crank pin.
A:
B:
C:
D:
E:

Top Ring Gap Position
Second Ring Gap Position
Upper Side Rail Gap Position
Lower Side Rail Gap Position

30 ~ 45

Piston Inspection

the carbon deposits off the piston.
• Clean
a new piston ring, use a gap gauge [A] to measure the
• Using
clearance between the ring groove and the ring.
Piston Ring Groove Clearance Service Limit (maximum)
Top Ring
Second Ring
FE120, 170, 250:
0.15 mm (0.0059 in)
0.12 mm (0.0047 in)
FE290, 350, 400:
0.16 mm (0.0063 in)
0.14 mm (0.0055 in)

If the measured value is greater than the service limit, replace the
piston with a new one.

3-40 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Piston and Connecting Rod
an inside micrometer, measure the pin hole bore of the piston
• Using
in several places.
Piston Pin Hole Bore Service Limit (maximum)
FE120:
14.033 mm (0.5525 in)
FE170:
16.033 mm (0.6312 in)
FE250:
18.033 mm (0.7100 in)
FE290:
19.033 mm (0.7493 in)
FE350, 400:
20.033 mm (0.7890 in)

If the measured value is greater than the service limit, replace the
piston with a new one.

Piston Pin Inspection

a micrometer,
• Using
places.

measure the piston pin diameter in several

Piston Pin Diameter Service Limit (minimum)
FE120:
13.975 mm (0.5502
FE170:
15.975 mm (0.6290
FE250:
17.975 mm (0.7077
FE290:
18.975 mm (0.7470
FE350, 400:
19.975 mm (0.7864

in)
in)
in)
in)
in)

If the measured value is smaller than the service limit, replace the
piston pin with a new one.
A: Piston Pin

Piston Ring Inspection
a micrometer,
• Using
several places.

measure the thickness of the piston ring in

Piston Ring Thickness Service Limit (minimum)
- for both Top and Second Rings
FE120, 170:
1.42 mm (0.056 in)
FE250, 290, 350, 400:
1.44 mm (0.057 in)

If the measured value is smaller than the service limit, replace the
piston rings as a set.

the piston ring inside the cylinder, and use the top of the piston to
• Fit
insert the piston ring perpendicularly to the skirt area at the bottom
of the cylinder. Then, use a gap gauge to measure the clearance of
the ring gap.
Piston Ring Gap Clearance Service Limit (maximum)
Top Ring
Second Ring
FE120, 170:
1.0 mm (0.039 in)
1.0 mm (0.039 in)
FE290, 350, 400:
1.2 mm (0.047 in)
1.2 mm (0.047 in)

If the measured value is greater than the service limit, replace the
piston rings as a set. (This is because of the difficulty in properly
measuring the oil ring.)
A: Piston Ring
B: Ring Gap Clearance

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-41
Piston and Connecting Rod
Connecting Rod Inspection

the big end of the connecting rod for wear or any traces of
• Inspect
seizure scratches or discoloration.
Abnormal wear or scratches could be caused by the presence of
foreign particles in the engine oil.
Vertical scratches or discoloration on the bearing surface is a
symptom that results from insufficient lubrication or overheating.
Clean the inside of the engine and change the engine oil.
Inspect and clean the cooling system.
Inspect the oil pump, oil filter, and oil passage and repair or replace
as needed.
When reusing the connecting rod or the crankshaft, carefully file off
any protrusions from their bearing surface.
an inside micrometer, measure the bore of the bearing area of
• Using
the small end in several places.
Connecting Rod Small End Bearing Area Bore Service Limit (maximum)
FE120:
14.042 mm (0.5528 in)
FE170:
16.047 mm (0.6318 in)
FE250:
18.051 mm (0.7107 in)
FE290:
19.051 mm (0.7500 in)
FE350, 400:
20.051 mm (0.7894 in)

•
•

If the measured value is greater than the service limit, replace the
connecting rod with a new one.
Mate the connecting rod cap to the big end of the connecting rod and
tighten the connecting rod bolts to the specified torque. Make sure to
apply engine oil to the threaded portion of the connecting rod bolts
before tightening them. (Refer to the section on Tightening Torque
Specifications.)
Using an inside micrometer, measure the bore of the bearing area of
the big end in several places.
Connecting Rod Big End Bearing Area Bore Service Limit (maximum)
FE120:
26.052 mm (1.0257 in)
FE170:
29.052 mm (1.1438 in)
FE250:
34.067 mm (1.3412 in)
FE290:
35.567 mm (1.4003 in)
FE350, 400:
37.567 mm (1.4790 in)

•

If the measured value is greater than the service limit, replace the
connecting rod with a new one.
Insert a bar each, measuring approximately 100 mm in length and
almost the same diameter as the respective bore into both the big
and small ends of the connecting rod. Then, set the V block and the
dial gauge as shown in the diagram in order to measure the bend
and twist of the connecting rod.
If the measured value is greater than the service limit, replace the
connecting rod with a new one.
Connecting Rod Bend and Twist Service Limit (maximum)
Service Limit:
0.15/100 mm (0.006/100 in)

A: Big End Bearing Area
B: Small End Bearing Area

3-42 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Piston and Connecting Rod
A: Dial Gauge
B: V Block

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-43
Cylinder Block and Crankcase Cover
Cylinder Inspection

the cylinder wall for the presence of any scratches,
• Inspect
cylinder exterior for any broken fins, and for any other damage.

•

the

If the cylinder has non-repairable damage, replace the cylinder block
with a new one.
Using a cylinder gauge, measure the cylinder bore in the longitudinal
and latitudinal directions at the locations given in the diagram on the
right.
Cylinder Bore Service Limit (maximum)
FE120:
60.067 mm (2.3648 in)
FE170:
66.067 mm (2.6011 in)
FE250:
76.067 mm (2.9948 in)
FE290:
78.067 mm (3.0735 in)
FE350:
83.067 mm (3.2703 in)
FE400:
87.067 mm (3.4278 in)
Cylinder Bore Roundness (maximum)
Service Limit: 0.56 mm (0.0220 in)

If the measurement shows that even one area of the cylinder has a
greater bore or roundness than the service limit, bore the cylinder to
an oversize or replace the cylinder block.
The oversize piston and piston rings come in + 0.50 mm (0.020 in)
oversize.
1. 10 mm (0.394 in)
2. Center Point
3. 8 mm (0.315 in)

Crankcase Cover
Disassembly
Drain the engine oil into an appropriate container.
Loosen the crankcase cover retaining bolts in the reverse sequence
of the tightening sequence given on the next page. Using a hammer
or a plastic mallet, gently tap on the crankcase cover at the area
where the cover is fastened to the engine, and remove the crankcase
cover.
A: Crankshaft Gear
B: Camshaft Gear
C: Timing Mark

•
•

Reassembly
Clean the mating surface and place a new gasket on it.
Apply high-temperature grease to the area in which the oil seal lip
faces the rotating shaft. Apply engine oil to the bearing areas.
Verify that the respective timing marks on the crankshaft gear and the
camshaft gear, as well as on the crankshaft gear and the balancer
gear (optional equipment on FE170) are properly aligned.

•
•
•

CAUTION
Make sure to remove the oil pump before installing the
camshaft. Serious damage to the engine will result if the
camshaft is installed with the oil pump in place.
A: Crankshaft
B: Timing Mark
C: Balancer Gear

3-44 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Cylinder Block and Crankcase Cover
that a crankshaft or the camshaft that requires an axial play
• Verify
adjustment shim is provided with an adjustment shim. (Refer to the

•
•

section on Axial Play Adjustment.)
Verify that the governor weight is closed. Also verify that the governor
arm is positioned so that its front receives the end of the governor
sleeve. (Refer to the section on Governor Mechanism.)
Install the crankcase cover while paying attention to the meshing of
the governor gear, evenly tighten the retaining bolts in the sequence
given in the diagram, and tighten them to the specified torque. (Refer
to the section on Tightening Torque Specifications.)

Ball Bearing

table below lists the areas in which ball bearings are used. An
• The
empty area signifies that the case acts directly as a plain bearing.
Ball Bearing Areas and Nominal Numbers
FE120

Crankshaft
Flywheel Side

FE250

FE290

Type D

Type G

Type D

Type G

Type D

Type G

6204

6305

6206

6204

6206

FE350, 400

Type D

Type G

Type D

Type G

6206

6306

6207

Camshaft
Balancer Shaft
Crankshaft

PTO Side

FE170

Camshaft
Balancer Shaft

6205

6204
-

6205
6205

6202

6206
-

Note: The numbers indicate the nominal numbers of the ball bearings.
inspect a ball bearing, first clean the bearing in solvent and allow
• To
it to dry. Then, apply engine oil and gently spin it with your hand.
If the bearing is noisy, does not spin smoothly, or has excessive play,
replace the bearing.

6306
-

6207
-

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-45
Cylinder Block and Crankcase Cover
Replace a ball bearing in the following manner:

the oil seal. Do not reuse an oil seal once it has been
• Remove
removed.
a bearing puller as shown in the diagram on the right, remove
• Using
the bearing.
the bearing housing and allow it to dry.
• Clean
Apply
oil
to a new bearing.
• Using a bearing
driver, drive the bearing in until it is flush with the
• end face of the housing.

Oil Seal

an oil seal is removed, replace it with a new one.
• Once
To
install
an oil seal, use a press or a seal driver.
• Only on the
side of the type D engine, the oil seal must be
• driven in 4 mmPTOlower
than the crankcase cover surface as shown in
the diagram. Other oil seals must be installed flush with the case
surface.
1. Oil Seal
2. Crankcase Cover

the area between oil seal lips [A] and [B] with high-temperature
• Fill
grease before installing the oil seal.

NOTE
Use a guide jig to install the oil seal without damaging its lip.
A: Lip A
B: Lip B
C: Crankcase or Crankcase Cover

Plain Bearing Area Inspection

a cylinder gauge, measure the bore of the plain bearing areas
• Using
of the cylinder block and the crankcase cover.
Plain Bearing Area Bore Service Limit (maximum)
FE120
Type D

(Unit: mm)
FE170

Type G

Type D

Type G

FE250
Type D

FE290

Type G

Crankshaft
Flywheel Side
(cylinder block)

Camshaft
Balancer Shaft

PTO Side
(crankcase
cover)

FE350, 400

Type D

Type G

Type D

30.075

35.075

Type G
35.075

(1.184 in)

(1.381 in)

15.063

16.063

20.063

23.063

(0.593 in)

(0.632 in)

(0.790 in)

(0.908 in)

–

15.063

(0.593 in)

Crankshaft
Camshaft
Balancer Shaft

15.063

16.063

20.063

23.063

(0.593 in)

(0.632 in)

(0.790 in)

(0.908 in)

–

Note: An empty area signifies that a ball bearing is used.
If the measured value is greater than the service limit, replace the part with a new one.

–

3-46 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Lubrication System
Lubrication Method
For FE120, 170, 250
As shown in the diagram on the right, the revolution of the crankshaft
causes the splash arm that is provided at the big end of the connecting
rod to pick up the engine oil from the crankshaft chamber and splash it
in a spray form to lubricate the internal parts. (Forced splashing type)

For FE290, 350, 400
A forced pumping lubrication method through the use of an oil pump
has been adopted. (Forced pumping type) The oil pump draws in the
oil and pumps the oil through the oil passages described below.
The oil pump is provided with a relief valve at its outlet side. When
the oil pressure is higher than the preset pressure of the relief valve,
the relief valve opens to discharge the oil into the crankcase. When the
oil pressure is lower than the preset pressure, the relief valve closes.
If the oil pressure becomes excessively high, it could break the seal in
the oil passage, critically damaging the engine.
For the oil passage on the FE350 and 400, refer to the following
section: Valve System - HLA.

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-47
Lubrication System

Oil Pump Disassembly and Reassembly
Disassembly
Remove the six retaining bolts from the oil pump cover and remove
the oil pump cover, gasket, and plate, in that order.
A: Retaining Bolts
B: Oil Pump Cover

•

the inner rotor and outer rotor, in that order.
• Remove
A: Inner Rotor
B: Outer Rotor

Reassembly

CAUTION
Make sure to install the camshaft before installing the oil
pump. If the camshaft is installed with the oil pump already in
place, it will cause serious damage to the engine.
A: Cutout at the End of Camshaft
B: Protrusion on the Inner Rotor
C: Oil Filter (FE350, 400 only)

3-48 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Lubrication System
reassembly is the reverse order of disassembly.
• The
the outer rotor and the inner rotor, in that order, making sure
• Install
to prevent dust from entering the oil pump.

CAUTION
To install the inner rotor, make sure that the protrusion [B] of
the inner rotor properly mates with the cutout [A] at the end
of the camshaft. If they are not mated correctly, it could cause
serious damage.

• On the FE350 and 400, verify that the oil filter [C] is securely fitted.

Oil Pump Inspection
The oil pressure specification is 31.4 kpa (3.2 kg/cm2, 0.46 psi)
minimum at the maximum no-load speed. If the oil pressure is low,
inspect the oil pump and the relief valve.
A: Spring
B: Relief Valve
C: Valve Seat
D: Inner Rotor
E: Outer Rotor
F: Plate
G: Gasket
H: Cover
I: Bolt
a gap gauge, measure the minimum clearance between the
• Using
inner and outer rotors.
Inner and Outer Rotor Clearance (maximum) - for FE290, 350, 400
Service Limit: 0.3 mm (0.012 in)

If the measured value is greater than the service limit, replace the
rotors as a set.
A: Gap Gauge

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-49
Lubrication System

• Using a micrometer, measure the following parts:
Inner Rotor Shaft Diameter (maximum) - for FE290, 350, 400
Service Limit: 12.627 mm (0.4971 in)
Outer Rotor Diameter (maximum) - for FE290, 350, 400
Service Limit: 40.467 mm (1.5932 in)
Outer Rotor Width (maximum) - for FE290, 350, 400
Service Limit
9.920 mm (0.3906 in)

Even if one of the measured values is smaller than the service limit,
replace the rotors as a set.
A: Innter Rotor Shaft Diameter
B: Outer Rotor Diameter
C: Outer Diameter Width
the relief valve and the valve seat contact area, and repair or
• Inspect
replace it with a new one if any abnormal condition is present.
• Using a vernier caliper, measure the free length of the relief spring.
Relief Spring Free Length (maximum) - for FE290, 350, 400
Service Limit: 19.0 mm (0.75 in)

If the measured value is smaller than the service limit, replace the
spring.
A: Valve Seat
B: Relief Valve
C: Spring

Oil Level Warning Device
The oil level warning device is incorporated in the electronic ignition
circuit. It consists of the following parts:
A: Igniter (LED: with oil warning light) (separate type)
Controller (LED: with oil warning light) (intergrated type)
B: Ignitioi Coil
C: Flywheel
D: Ignition Plug
E: Oil Level Sensor Switch

3-50 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Lubrication System

Oil Level Sensor Switch
If the oil level becomes lower than the preset value, the sensor switch
[A] closes. As a result, the base current [IB1] passes through the Zener
diode [Z1] and the resistor [R12] to flow to [TR1] to maintain the circuit.
The base current [IB1] is held by the amplified collector current [IC1],
and as a result, the spark current does not generate, causing the engine
to stop. (Refer to the section on Ignition System for comparison.)
A: Oil Level Sensor Switch
ESW: Engine Switch

Inspection method
Verify that the oil level of the engine is normal.
Disconnect the wire from the oil level sensor terminal.
Set the measurement range of the tester to R 2 1 and connect one
of the tester leads to the terminal of the sensor and the other end to
ground. The tester should read ∞.
If the tester does not read ∞, the oil level sensor switch is faulty.
Gently lift the PTO side to tilt the engine.

•
•
•
•

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-51
Lubrication System
the engine is tilted to a certain angle, the tester should read 0
• When
.
If the tester does not read 0 , but remains at ∞, the oil level sensor
switch is faulty.
A: Terminal
B: O-ring
C: Clamp
D: Oil Level Sensor Switch

Igniter (with oil level warning light) Inspection (separate type)
Verify that the oil level in the engine is normal.
Disconnect the wire from the oil level sensor terminal.
Start the engine and operate it at a low speed.
Connect one of the test leads to the wire that was disconnected in
step 2 above, and the other end to the engine ground to stop the
engine.
If the engine does not stop, inspect the wires and connections.
If the wires and connections are normal, the igniter (with oil level
warning light) is faulty and must be replaced.
Connect the test leads in the same way as in step 4 above and start
the engine again.
If the oil level warning light illuminates and the engine does not start,
the system is normal.
If the oil level warning light does not illuminate, the oil level warning
light (LED) is faulty and the igniter must be replaced.
A: Test Lead
B: Connection
C: Oil Level Sensor Terminal

•
•
•
•

•

Controller (with oil level warning light) inspection (integrated type)
Verify that the oil level in the engine is normal.
Disconnect the wire from the oil level sensor terminal.
Start the engine and operate it at a low speed.
Connect one of the test leads to the wire that was disconnected in
step 2 above, and the other end to the engine ground to stop the
engine.
If the engine does not stop, inspect the wires and connections.
If the wires and connections are normal, the controller (with oil level
warning light) is faulty and must be replaced.
Connect the test leads in the same way as in step 4 above and start
the engine again.
If the oil level warning light illuminates and the engine does not start,
the system is normal.
If the oil level warning light does not illuminate, the oil level warning
light (LED) is faulty and the controller must be replaced.

•
•
•
•

•

3-52 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Lubrication System
Breather
The function of the breather is to maintain a vacuum in the crankcase
to prevent the engine oil from being discharged outside the engine.
The breather valve regulates the flow of the air that is created by the
movement of the piston by allowing the air to flow from the inside of the
crankcase to the outside, while preventing the air from the outside of
the crankcase to enter inside.
In the rocker case, the maze and the volumetric expansion of the
rocker case causes the air containing oil to separate into oil and air.
The air from the crankcase ultimately flows to the air cleaner and mixes
with the intake air.
Inspection Method
With the rocker case installed in place, blow air or apply suction to
the breather pipe in order to activate the breather valve. Verify that
the breather valve closes when air is blown into the pipe.
Remove the retaining screws from the breather valve, and inspect the
valve and valve seat for the presence of damage, cracks, or wear.
Using a gap gauge, measure the clearance between the breather
valve and valve seat.
A: Rocker Case
B: Breather
C: Oil Level Sensor Terminal

•
•
•

A: Breather Valve
B: Retaining Screw

Breather Valve Air Gap (maximum)
Service Limit: 0.2 mm (0.008 in)

If the air gap is greater than the service limit or if the breather valve
is defective, replace the breather valve with a new one.
A: Retaining Screw
B: Backing Plate
C: Breather Valve
D: Air Gap

Air Filter (cartridge type)
With the cartridge type oil filter, the engine oil change interval can
be extended to 100 hours. (The engine oil must be changed every 50
hours in an engine without the cartridge type filter.)
Ordinarily, the engine oil flows in the following order: entrance [A]
element [B]
exit [C].
If the element becomes clogged, the oil flows through the bypass
[D], thus preventing the engine from operating without oil, although the
filtering function is bypassed.

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-53
Lubrication System
Oil Filter Replacement Procedure

NOTE
Be careful with hot oil to prevent burns.
Always use a genuine Kawasaki oil filter for replacement. Other
brands of oil filters may also fit but they may be of poor quality.
the engine oil into an appropriate container.
• Drain
the oil filter by turning it counterclockwise.
• Remove
oil to the seal [E] of the new oil filter.
• Apply
the new oil filter clockwise until its seal [E] comes in contact with
• Turn
the mating surface. Then, turn the oil filter by hand an additional 3/4

•
•
•

turn.
Pour in the specified amount of engine oil.
Start the engine, operate it approximately 3 minutes, and then stop
the engine. Inspect around the oil filter to make sure that there is no
oil leak.
The oil level decreases by an amount that is equivalent to the capacity
of the oil filter. Replenish the oil to this amount.

3-54 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Crankshaft
Disassembly

the crankcase cover.
• Remove
If
axial
play
adjustment shims are provided for the crankshaft and the
• camshaft, remove
the shims and identify them so that they can be

•
•
•

installed correctly during reassembly.
Place the cylinder block on a base so that the flywheel side faces
down. Keep the tappet (or the HLA on FE350 or 400) pushed up
towards the cylinder head.
After aligning the matching marks on the crankshaft gear and the
camshaft gear, take out the camshaft.
Remove the tappet (or the HLA on FE350 or 400) from the crankcase
and place an identification mark on it so that the tappet can be
reinstalled in its original position.
After taking out the HLA of the FE350 or 400, keep the side in which
the snap ring is visible upright. If it is placed on its side or upside
down, the oil that is sealed in the HLA unit could leak out, disabling
the HLA function.

the FE250, 290, 350, or 400 engine, remove the retaining nuts
• On
[H] from the balancer guide [G], and pull out the balancer guide from

•
•

the crankcase [D].
Remove the connecting rod bolts and the connecting rod cap.
Remove the crankshaft from the crankcase. If it is equipped with a
balancer, take out the complete crankshaft assembly as is from the
crankcase.

NOTE
Be careful not to damage the oil seal.

A:
B:
C:
D:
E:
F:
G:
H:

Crankshaft
Crankshaft Gear
Governor Drive Gear
Balancer Link Rod
Balancer Weight
Spacer
Key
Shim

On Type G, however, the link rod on the crankshaft gear side cannot
be disassembled because the crankshaft gear is pressed in.

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-55
Crankshaft
Crankshaft Inspection

the crank pin and the journal for galling, wear, or rust.
• Inspect
If the crank pin exhibits damage as described above, carefully inspect

•
•

and repair the big end of the connecting rod, or replace the connecting
rod or the crankshaft with a new part.
Inspect the crankshaft gear for abnormal wear or damaged teeth.
If the crankshaft gear is worn as described above, replace the
crankshaft gear with a new one.
Using a micrometer, measure the diameter of both journals of the
crankshaft, the diameter of the journal for the balancer link rod, and
the diameter of the crank pin in several places.
If the measured value is smaller than the service limit given below,
replace the crankshaft with a new one.
Crankshaft Journal Diameter Service Limit (minimum)

TPO Side
Journal
Diameter

Flywheel Side
Balancer Link Rod Journal

Crankpin Diameter

(unit: mm)

FE120

FE170

FE250

FE290

19.930
(0.7846 in)
19.930
(0.7846 in)

24.930
(0.9815)
24.930
(0.9815)

–

25.944
(1.0214 in)

28.944
(1.1395 in)

29.930
(1.1783 in)
29.930
(1.1783 in)
46.924
(1.8474 in)
33.944
(1.3394 in)

29.930
(1.1783 in)
29.930
(1.1783 in)
46.924
(1.8474 in)
35.444
(1.3954 in)

center support tools [B] as shown in the diagram, support both
• Using
ends of the crankshaft. Place a dial gauge [A] on the journal and
slowly turn the crankshaft to measure the fluctuation (the variance
between the maximum and minimum values) of the dial gauge, which
is the runout of the crankshaft.
Crankshaft Runout Service Limit (maximum)
Service Limit: 0.5 mm (0.02 in) (TIR)

If the measured value is greater than the service limit, replace the
crankshaft with a new one.

Crankshaft Axial Play Adjustment
If a part that affects the axial play has been replaced, the axial play
must be adjusted as described below. Shim adjustment is not available
on the FE120 and 170. Note: Except the FE170 for pump application.
Place a gasket on the crankcase and measure and record the
distance from the gasket surface to the crankshaft gear surface
(measurement A).
Measure and record the distance from the crankcase cover mating
surface to the end face of the crankshaft bearing inner race (measurement B).
Place these measurements on the crankshaft shim selection table,
and trace the respective line.
Select the next thinner shim that appears on the shim selection table.
For example, on the FE290, if measurement [A] is 14.62 mm (0.576
in) and measurement [B] is 16.18 mm (0.637 in), the correct shim
thickness is t = 1.33 mm.
A: Measurement [A]
B: Measurement [B]
C: Crankcase Cover
D: Crankcase
E: Gasket

•
•
•
•

FE350, 400
34.930
(1.3752 in)
34.930
(1.3752 in)
49.924
(1.9655 in)
37.444
(1.4742 in)

3-56 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Crankshaft

For example, on the FE350, if measurement [A] is 15.87 mm and
measurement [B] is 17.66 mm, the correct shim thickness is t = 1.53
mm.
Crankshaft Axial Play Standard and Service Limit (maximum)

(unit: mm)

Standard

Service Limit

FE120

0 ~ 0.24 (0 ~ 0.009 in)

0.5 (0.0197 in)

FE170

0.03 ~ 0.30 (0.0011 ~ 0.0118 in)

0.5 (0.0197 in)

FE250

0.05 ~ 0.17 (0.0020 ~ 0.0067 in)

0.35 (0.0138 in)

FE290

0.09 ~ 0.20 (0.0035 ~ 0.0079 in)

0.35 (0.0138 in)

FE350, 400

0.08 ~ 0.22 (0.0031 ~ 0.0087 in)

0.35 (0.0138 in)

Reassembly
The reassembly is the reverse order of disassembly.

the mating surfaces of the crankcase and the crankcase cover
• Clean
of any residues and install a new gasket.
high-temperature grease to the lip of the crankcase oil seal.
• Apply
(Refer to the section on Oil Seal.) Apply oil to the journals of each
part.

the FE221 ~ 400 with a reciprocal movement balancer, install the
• On
reciprocal movement balancer parts on the crankshaft. (Refer to the
section on Balancer.)

the crankshaft in the crankcase, making sure not to damage the
• Install
oil seal lip with the key groove at the tapered area of the crankshaft.

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-57
Balancer
Engine vibration is generated primarily by the inertia that is created
through the reciprocal movement mass such as the piston, piston pin,
piston ring, and the small end of the connecting rod.
On the FE400, 350, 290, and 250, a reciprocal movement balancer
system in which balance weight is linked to the crankshaft has been
adopted. This is the most effective method for canceling the inertia that
is generated by the reciprocal movement mass, thus reducing vibration.
A: Crankshaft
B: Link Rod
C: Spacer
D: Crankcase
E: Balance Weight
F: O-ring
G: Balancer Guide
H: Nut

The FE170 can be provided with a uniaxial rotation balancer as a
factory option.
A: Crankshaft
B: Balancer Drive Gear
C: Balancer Shaft
D: Balancer Gear

3-58 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Balancer
Reciprocal Movement Balancer (FE400, 350, 290, 250)
Disassembly
Remove the retaining nuts from the balancer guide and pull out the
balancer guide from the crankcase.
Remove the connecting rod bolt and remove the connecting rod cap.
Turn the crankshaft to be near the top-dead-center to push the

connecting rod up. Then, turn the crankshaft 90 counterclockwise
as viewed from the PTO side. Remove the crankshaft (together with
the balancer) from the crankcase, through an area in which it does
not interfere with the connecting rod.

•
•
•

NOTE
Be careful not to damage the oil seal when removing the crankshaft.

• Remove the balancer link rod from the crankshaft.
NOTE
The balancer link rod on the PTO side cannot be disassembled
because the crankshaft gear is pressed in.
Inspection and Repair
Using a micrometer, measure the bearing bore of the big and small
ends of the link rod in several places.

•

Link Rod Bearing Bore Service Limit (maximum)

(Unit: mm)

Small End Bore

Big End Bore

FE250

12.057 (0.4747 in)

47.106 (1.855 in)

FE290

12.064 (0.4750 in)

47.126 (1.855 in)

FE350, 400

12.057 (0.4747 in)

50.106 (1.973 in)

A: Link Rod Big End Bearing Bore
B: Small End Bearing Bore

•

If the measured value is greater than the service limit, replace the
link rod. On the FE290, the bushing can be replaced.
Replace the link rod bushing as follows:
Support the big end of the link rod as described in the diagram, and
use a driver to pull the bushing out.
A: Bushing Driver
B: Bushing
C: Link Rod
D: Tool Base

the disassembled parts and allow them to dry.
• Wash
engine oil to the new bushing.
• Apply
a bushing driver, install the bushing so that the gap of the
• Using
bushing is positioned as shown in the diagram. Drive the bushing so
that it is 1mm deeper than the end face of the link rod.
A: Depression
B: Bushing Gap

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-59
Balancer
a micrometer, measure the balancer guide hole bore of the
• Using
balance weight in several places.
Balancer Guide Hole Bore Service Limit (maximum)
FE250, 290:
FE350, 400:

26.118 mm (1.0283 in)
26.097 mm (1.0274 in)

If the measured value is greater than the service limit, replace the
balance weight. On the FE350 and 400, the bushing can be replaced.
A: Guide Hole
B: Balance Weight

NOTE
To install a new bushing, drive it in so that the end face of the
bushing is flush with the end face of the balance weight as shown
in the diagram on the right.
A: Bushing
B: Balance Weight

a micrometer, measure the diameter of the balancer guide in
• Using
several places.
Balancer Guide Diameter Service Limit (minimum)
FE250, 290, 350, 400:

25.907 mm (1.0593 in)

If the measured value is smaller than the service limit, replace the
balancer guide with a new one.

Reassembly
Make sure to apply fresh engine oil to the sliding and rotating areas.
2. Install the balancer on the crankshaft in the following order:
Balance weight
link rod
spacer

•

NOTE
Install the spacer with its chamfered end facing the link rod.
A Balancer Weight
B: Spacer
C: Link Rod

Uniaxial Rotation Balancer (FE170)
Disassembly
Remove the crankcase cover and align the matching marks on the
balance drive gear of the crankshaft and the balance gear.
Take out the balancer shaft from the crankcase.

•
•

Inspection
Inspect the balancer gear for wear or broken teeth.
If the gear is excessively worn, replace the balancer shaft.
Using a micrometer, measure the diameter of the balancer journal in
several places.

•
•

3-60 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Balancer
Balancer Shaft Journal Diameter Service Limit (minimum)
FE170:

PTO Side
14.943 mm (0.5883 in)

Flywheel Side
14.933 mm (0.5879 in)

If the measured value is smaller than the service limit, replace the
balancer shaft.
* For details on the bore of the balancer shaft bearing hole, refer to
the section on Crankcase/Plain Bearing.
A: Crankshaft
B: Balancer Gear
C: Matching Mark

Reassembly
Install the balancer shaft in the crankcase by aligning the matching
mark on the balancer gear with the matching mark on the balancer
drive gear of the crankshaft.

•

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-61
Camshaft
Disassembly

the crankcase cover.
• Remove
If
axial
play
adjustment shims are provided for the crankshaft and the
• camshaft, remove
the shims and identify them so that they can be

•
•

NOTE
Clean the mating surfaces of the crankcase and the crankcase
cover of any gasket residues.

• Take out the tappet or the HLA from the crankcase.
NOTE
After removing the tappet, place marks on them to identify the
intake and exhaust tappets so that they can be reinstalled in their
original positions.
Keep the end of the HLA in which the snap ring is visible upright.
If it is placed on its side, the oil that is sealed in the unit could leak
out, disabling the HLA function.
A: Matching Marks

Inspection

the camshaft and cam gear for any broken teeth or wear.
• Inspect
If they are abnormally worn or have broken teeth, replace the
camshaft with a new one.

the camshaft to make sure that its automatic compression
• Inspect
Reduction (ACR) function operates smoothly and does not have any
damage or abnormal wear.
When the weight [C] is closed, if the top of the arm [A] is lower than
the base [B], replace the ACR with a new one.
When the weight [C] is pulled entirely outward with your finger, if the
top of the arm [A] is higher than the cam base [B], replace the ACR
with a new one.
If ACR parts are worn, replace the ACR with a new one.

3-62 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Camshaft

• Using a micrometer, measure the camshaft journal in several places.
Camshaft Journal Diameter Service Limit (minimum)
PTO Side

FE120
FE170
FE250
FE290
FE350, 400

(Unit: mm)
Flywheel Side

Type D

Type G

Type D, G

14.910
(0.5870 in)
15.910
(0.6264 in)
19.927
(0.7845 in)
22.927
(0.9026 in)
22.927
(0.9026 in)

19.930
(0.7846 in)
24.930
(0.9815 in)
29.930
(1.1783 in)
29.930
(1.783 in)
34.930
(1.3752 in)

14.910
(0.5870 in)
15.910
(0.6264 in)
22.927
(0.9026)
22.927
(0.9026 in)
22.927
(0.9026 in)

If the measured value is smaller than the service limit, replace the
camshaft with a new one.
a vernier caliper, measure the overall height of the cam of the
• Using
camshaft.
Cam Overall Height Service Limit (minimum) - for Intake and Exhaust
FE120:
FE170:
FE250:
FE290:
FE350, 400:

26.157 mm (1.0298 in)
30.024 mm (1.1820 in)
31.04 mm (1.2220 in)
32.70 mm (1.2874 in)
33.24 mm (1.3087 in)

If the measured value is smaller than the service limit, replace the
camshaft with a new one.

Reassembly

• Make sure to reinstall the camshaft with the oil pump removed.
CAUTION
If the camshaft is reinstalled with the oil pump attached to it,
it will cause serious damage to the engine.
the cylinder block on a base with the flywheel side facing down.
• Place
Reinstall
or the HLAs in their original positions in
• accordancethewithtappets
the intake and exhaust identification marks. Push

•

the tappets or the HLAs all the way against the cylinder head so that
they will not obstruct the installation of the camshaft.
With the matching marks of the crankshaft gear and the camshaft
gear aligned, install the camshaft in the crankcase.

NOTE
On the FE290, FE350, and FE400, verify that the tab [B] of the
oil pump is securely fitted into the groove [A] at the end of the
camshaft.
A: Groove at end of camshaft
B: Oil Pump Tab

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-63
Camshaft
A: Matching Marks

Camshaft Axial Play Adjustment
If a part that affects the axial play has been replaced, the axial play
must be adjusted as described below.
Shim adjustment is not available on the FE120 and 170.
Place a gasket on the crankcase and measure and record the
distance from the gasket surface to the crankshaft gear surface
(measurement A).
A Measurement [A]
B: Measurement [B]
C: Crankcase Cover
D: Crankcase
E: Gasket

•

and record the distance from the crankcase cover mating
• Measure
surface to the end face of the crankshaft bearing inner race (mea-

•
•

surement B).
Apply these measurements on the crankshaft shim selection table,
and trace the respective line.
Select the next thinner shim that appears on the shim selection table.
For example, on the FE290, if measurement [A] is 14.62 mm and
measurement [B] is 16.24 mm, the correct shim thickness is t =1.38
mm.

NOTE
The FE290D camshaft has no shim adjustment.

3-64 DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE
Camshaft

DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-65
Camshaft
Apply these measurements on the crankshaft shim selection table,
and select the next thinner shim.
For example, on the FE350D, if measurement [A] is 13.41 mm and
measurement [B] is 14.09 mm, the correct shim thickness is t = 0.4
mm.

For example, on the FE350G, if measurement [A] is 15.85 mm and
measurement [B] is 17.70 mm, the correct shim thickness is t =1.60
mm.

Cam Shaft Axial
- for Type G

Play

Standard

and

Service

Limit

(maximum)
(Unit: mm)

Srandard

Service Limit

FE120, 170

0.08 ~ 0.34 (0.0031 ~ 0.0134 in)

0.50 (0.0197 in)

FE250

0.05 ~ 0.17 (0.0020 ~ 0.0067 in)

0.35 (0.0138 in)

FE290, 350, 400

0.07 ~ 0.21 (0.0028 ~ 0.0083 in)

0.35 (0.0138 in)

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Kawasaki FE290 User Manual To The E7933203 045b 4f54 B9ce 8c1cca4d5bd1

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