Kawasaki FH381V, FH430V Service Manual
FH381V FH430V
4–stroke air cooled v-twin gasoline engine
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of
Quality Assurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been
taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such
changes to products manufactured previously.
All information contained in this publication is based on the latest product information available at the time of publication.
Illustrations and photographs in this publication are intended for reference use only and may not depict actual model
component parts.
© 2001 Kawasaki Heavy Industries, Ltd. First Edition (1) : Oct. 1, 2001 (K)
LIST OF ABBREVIATIONS
A ampere(s) lb pound(s)
ABDC after bottom dead center m meter(s)
AC alternating current min minute(s)
ATDC after top dead center N newton(s)
BBDC before bottom dead center Pa pascal(s)
BDC bottom dead center PS horsepower
BTDC before top dead center psi pound(s) per square inch
C
DC direct current rpm revolution(s) per minute
F farad(s) TDC top dead center
F degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
g gram(s) W watt(s)
h hour(s)
L liter(s)
degree(s) Celsius r revolution
ohm(s)
Read OWNER’S MANUAL before operating.
EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaustemission
(2) control systems (EM) in compliance with applicable regulations of the United States Environmental Protection Agency
and California Air Resources Board.
Crankcase Emission Control System
1.
A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow-by
gases are led to the breather chamber through the crankcase. Then, it is led to the air cleaner.
Oil is separated from the gases while passing through the inside of the breather chamber from the
crankcase, and then returned back to the bottom of crankcase.
2. Exhaust Emission Control System
The exhaust emission control system applied to this engine consists of a carburetor and an ignition
system having optimum ignition timing characteristics.
The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel
economy with a suitable air cleaner and exhaust system.
TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED
Federal law and California State law prohibits the following acts or the causing thereof: (1) the removal or rendering
inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of
design incorporated into any new engine for the purpose of emission control prior to its sale or delivery to the ultimate
purchaser or while it is in use, or (2) the use of the engine after such device or element of design has been removed or
rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
Do not tamper with the original emission related part:
Carburetor and internal parts
•
Spark plugs
•
Magneto or electronic ignition system
•
Fuel filter element
•
Air cleaner elements
•
Crankcase
•
Cylinder heads
•
Breather chamber and internal parts
•
Intake pipe and tube
•
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 this manual, the product is divided into its major systems and these systems make up the manual’s chapters.
The Quick ReferenceGuideshowsyoualloftheproduct’s
system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents.
For example, if you want ignition coil information, use
the Quick ReferenceGuidetolocatetheElectrical System
chapter. Then, use the Tableof Contents on the first page
of the chapter to find the Ignition coil section.
Whenever you see these WARNING and CAUTION
symbols, heed their instructions! Always follow safe
operating and maintenance practices.
This warning symbol identifies special instruc-
tions or procedures which, if not correctly fol-
lowed, could result in personal injury, or loss of
life.
CAUTION
This caution symbol identifies special instruc-
tions or procedures which, if not strictly ob-
served, could result in damage to or destruction
of equipment.
This manual contains four more symbols (in addition to
WARNING and CAUTION) which will help you distinguish
different types of information.
NOTE
This note symbol indicates points of particular interest for more efficient and convenient operation.
Indicates a procedural step or work to be done.
•
Indicates a procedural sub-step or how to do the work
of the procedural step it follows. It also precedes the
text of a WARNING, CAUTION, or NOTE.
Indicates a conditionalsteporwhataction 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
Model Identification...........................................................................................................................................................1-4
General Specifications......................................................................................................................................................1-5
Torque and Locking Agent................................................................................................................................................1-6
Special Tools.....................................................................................................................................................................1-8
1
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 Crack Hardening Warp
Bent Dent Scratch Wear
Color change Deterioration Seizure
(20) Specifications
Specification terms are defined as follows:
"Standards" show dimensions or performances which brand-new parts or systems have.
"Service Limits" indicate the usable limits. If the measurement shows excessive wear or deteriorated performance,
replace the damaged parts.
1-4 GENERAL INFORMATION
Model Identification
Electric Starter Model
Recoil Starter Model
Cylinder Number Designation:
No.1 Cylinder is the left-hand cylinder viewed from the air cleaner.
No.2 Cylinder is the right-hand cylinder viewed from the air cleaner.
General Specifications
GENERAL INFORMATION 1-5
Items
Type of engine
Cylinder layout 90 V-Twin
Bore x Stroke 65 mm x 65 mm (2.56 in x 2.56 in)
Piston displacement 431 mL (26.3 cu. in)
Direction of rotation Counterclockwise facing the PTO shaft
Compression release Automatic compression release
Low idle speed 1550 rpm
Fast idle speed 3600 rpm
Ignition system Transistorized-fly wheel magneto
RFI Per Canada and U.S.A. requirements
Starting system Electric starter and/or recoil starter
Charging system 12 V - 15 amps with regulator
Spark plug CHAMPION RCJ8Y
Carburetor Float type, fixed main jet
Fuel pump Diaphragm type pulse pump
Air cleaner Dual stage element, dry type
Governor Flyweight all speed governor
Lubrication system Pressure feed by positive displacement pump
Oil filter Cartridge type full flow filter
Oil capacity
(when engine is
completely dry)
Cooling system Forced air cooling by fan
Dimensions (L x W x H ) 421 mm x 350 mm x 325 mm
Electric starter model (16.6 in x 13.8 in x 12.8 in)
Recoil starter model (16.6 in x 13.8 in x 13.9 in)
Dry weight
Electric starter model 31.8 kg (70.1 lb)
Recoil starter model 29.8 kg (65.7 lb)
Forced air-cooled, vertical shaft, OHV, 4-stroke gasoline engine.
1.8 L (1.9 US-qt)
421 mm x 350 mm x 353 mm
FH381V, FH430V
Specifications subject to change without notice.
1-6 GENERAL INFORMATION
Torque and Locking Agent
The following tables list the tightening torque for the major fasteners, and the parts requiring use of a non-permanent
locking agent or liquid gasket.
Letters used in the "Remarks" column mean:
L:Apply a non-permanent locking agent to the threads.
M:Apply a molybdenum disulfide lubricant (grease or oil) to the threads, seated surface, or washer.
O:Apply an oil to the threads, seated surface, or washer.
S:Tighten the fasteners following the specified sequence.
SS : Apply silicone sealant.
Fastener
1
m
Fuel System:
Throttle Valve Screws 0.7 0.07 6in1lb
Main Jet 2.3 0.23 20 in1lb
Float Chamber Mounting Bolt 4.5 0.46 40 in-lb
(Carburetor)
Governor Arm Clamp Nut 7.8 0.80 69 in1lb
Governor Shaft Plate Screws 2.0 0.20 18 in-lb
Holder Plate Nuts (Air Cleaner, 5.9 0.60 52 in
Carburetor Mounting)
Intake Manifold Mounting Bolts 6.9 0.70 61 in1lb =S
Cleaner Body Mounting Bolts 5.9 0.60 52 in
Control Panel Mounting Bolts 5.9 0.60 52 in1lb
Cooling System:
Engine-shroud Bolt (M8) 15 1.5 11
Engine-shroud Bolts (M6) 5.9 0.60 52 in
Engine-shroud Bolts (Studs) 7.8 0.80 69 in
Plug Screw (Engine-shroud) 3.4 0.35 30 in
Flywheel Bolt 56 5.7 41
Engine Top End
Cylinder Head Bolts 25 2.6 19 =S
Valve Clearance Lock Screws 6.9 0.70 61 in
Connecting Rod Big End 5.9 0.60 52 in1lb =O
Cap Bolts
Rocker Arm Bolts 28 2.8 20
Rocker Cover Mounting Bolts 5.9 0.60 52 in
Exhaust Pipe Flange Nuts 15 1.5 11
Spark Plugs 22 2.2 16
N
Torque
kgf1m ft1lb
1
lb
1
lb
1
lb
1
lb
1
lb
1
lb
1
lb
Remarks
Torque and Locking Agent
GENERAL INFORMATION 1-7
Fastener
1
m
Lubrication System:
Engine Drain Plugs 6.9 0.70 61 in1lb
Oil Passage Plug 3.9 0.40 35 in1lb
Oil Pump Cover Plate Mounting Bolts 5.9 0.60 52 in1lb
Oil Filter in the text
Camshaft/Crankshaft:
Crankcase Cover Bolts
Breather Chamber Cover Bolts 5.9 0.60 52 in1lb
Electrical System:
Starter Coil Screws 3.4 0.35 30 in
Flywheel Bolt 56 5.7 41
Fan Housing Bolts 5.9 0.60 52 in1lb
Screen Screws 5.9 0.60 52 in
Regulator Screws 3.4 0.35 30 in1lb
Ignition Coil Bolts (Studs) 7.8 0.80 69 in1lb
Ignition Coil Bolts (Bolts) 5.9 0.60 52 in
Starter Motor Mounting Bolts 15 1.5 11
Starter Motor Through Bolts 3.9 0.40 35 in1lb
Recoil Starter Mounting Nuts 5.9 0.60 52 in
Recoil Starter Retainier Screw 7.8 0.80 69 in
Spark Plugs 22 2.2 16
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this
table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry
solvent-cleaned threads.
N
25 2.6 19.0 =S
Torque
kgf1m ft1lb
1
lb
1
lb
1
lb
1
lb
1
lb
Remarks
Basic Torque for General Fasteners
Threads dia
Torque
(mm) N1m kgf1m ft1lb
4 2.0 0.20 17 in
5 3.4 0.35 30 in
6 5.9 0.60 52 in-lb
8 15 1.5 11
1
lb
1
lb
1-8 GENERAL INFORMATION
Special Tools
Piston Ring Pliers: 57001–115
Oil Pressure Gauge, 5kgf/cm2: 57001–125
Compression Gauge: 57001–221
Piston Ring Compression Belt, Ø55 – Ø67: 57001–1096
Valve Seat Cutter, 45- Ø27.5: 57001–1114
Valve Seat Cutter, 32- Ø25.0: 57001–1118
Oil Pressure Gauge Adapter, PT 1/8: 57001–1033
Piston Ring Compression Grip: 57001–1095
Valve Seat Cutter, 32- Ø28.0: 57001–1119
Valve Seat Cutter Holder Bar: 57001–1128
Special Tools
GENERAL INFORMATION 1-9
Compression Gauge Adapter M14 x 1.25: 57001–1159
Oil Filter Wrench: 57001–1249
Valve Seat Cutter Holder Ø6: 57001–1360
Kawasaki Bond (Silicone Sealant) : 56019–120
Hand Tester: 57001–1394
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart..............................................................................................................................................2-2
Specifications....................................................................................................................................................................2-3
Periodic Maintenance Procedures....................................................................................................................................2-4
Fuel System...................................................................................................................................................................2-4
Low Idle Speed Adjustment.......................................................................................................................................2-4
High Idle Speed Adjustment......................................................................................................................................2-4
Fuel system Cleanliness Inspection...........................................................................................................................2-5
Fuel Pump Inspection................................................................................................................................................2-5
Fuel Filter Inspection..................................................................................................................................................2-5
Air Element Removal..................................................................................................................................................2-6
Air Element Installation..............................................................................................................................................2-6
Air Element Cleaning and Inspection.........................................................................................................................2-6
Air Cleaner Housing (Case and Body) Inspection.....................................................................................................2-7
Engine Top End.............................................................................................................................................................2-7
Cylinder Head Cleaning and Inspection....................................................................................................................2-7
Valve Clearance Inspection........................................................................................................................................2-8
Valve Clearance Adjustment......................................................................................................................................2-8
Valve Seat Inspection.................................................................................................................................................2-9
Valve Seat Repair.......................................................................................................................................................2-9
Lubrication System......................................................................................................................................................2-11
Oil Level Inspection..................................................................................................................................................2-11
Oil Change...............................................................................................................................................................2-12
Oil Filter Change......................................................................................................................................................2-12
Oil Filter Installation..................................................................................................................................................2-12
Electrical System.........................................................................................................................................................2-13
Spark Plug Cleaning and Inspection........................................................................................................................2-13
Spark Plug Gap Inspection......................................................................................................................................2-13
2
2-2 PERIODIC MAINTENANCE
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 (
Some adjustments require the use of special tools or other equipment. An electronic tachometer will facilitate setting
idle and running speeds.
●) designates that the corresponding item should be performed at that interval.
OPERATION
Check or clean air intake screen
Check and add engine oil
Check for fuel and oil leakage
Check for loose or lost nuts and
screws
Check battery electrolyte level
Clean air cleaner foam element (1)
Clean air cleaner paper element (1)
Clean dust and dirt from cylinder and
cylinder head fins (1)
Tighten nuts and screws
Change engine oil
Clean and re-gap spark plugs
Change Oil filter
Change air cleaner paper element (1)
Check and adjust valve clearance
Clean and lap valve seating surface
Clean combustion chamber
Daily First
8hr.
•
•
•
•
•
• •
Every
25 hr.
•
INTERVAL
Every
50 hr.
•
Every
100 hr.
•
•
•
Every
200 hr.
•
•
Every
300 hr.
•
•
•
Refer-
ence
P11
P6~P7
P6~P7
P12
P13
P12
P6~P7
P8
P9~P11
P7
(1): Service more frequently under dusty conditions.
: These items must be performed with the proper tools. See your authorized Kawasaki Engine Dealer for service,
unless you have the proper equipment and mechanical proficiency.
Specifications
PERIODIC MAINTENANCE 2-3
Item
Standard
Fuel System
Idle speed: (1)
Low idle speed 1550 r/min (rpm)
High idle speed 3600 r/min (rpm)
Air cleaner:
Type Dual stage filtration system
Pre-cleaner Foam element
Second-stage cleaner Paper element
Engine Top End
Valve clearance Intake, Exhaust 0.10 ~ 0.15 mm (0.004 ~ 0.006 in.)
Valve seating surface angle Intake, Exhaust 45
Valve seating surface width Intake, Exhaust 0.6 ~ 0.9 mm (0.024 ~ 0.035 in.)
Lubrication System
Engine oil
Type SF, SG, SH or SJ class
Viscosity SAE40, SAE30,
SAE10W-30/10W-40 or SAE5W-20
Capacity [When filter is not removed]
1.5 L (1.6 US qt)
[When filter is removed]
1.7 L (1.8 US qt)
[When engine is completely dry]
1.8 L (1.9 US qt)
Level Operating range (grid area) on dipstick
Electrical System
Spark plug gap 0.75 mm (0.030 in.)
(1) Idle speeds may vary depending on each equipment. Refer to the equipment specification.
Special Tools - Valve Seat Cutter, 45- 27.5 : 57001–1114
Valve Seat Cutter, 32
Valve Seat Cutter, 32
Valve Seat Cutter Holder Bar : 57001–1128
Valve Seat Cutter Holder Oil Filter Wrench : 57001–1249
25.0 : 57001–1118
-
28.0 : 57001–1119
-
6.0 : 57001–1360
2-4 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Fuel System
Low Idle Speed Adjustment
Disconnect all possilble external loads from the engine.
•
Start the engine and warm it up thoroughly.
•
Always keep your hands clear of the moving parts.
Move the throttle lever on dash to the idle position, and hold the
•
throttle lever on the carburetor in closed position (turn the governor
arm clockwise all the way) and adjust the low idle speed screw [A]
until the engine idles at specified speed.
Idle Speed (Carburetor idle rpm)
1450 rpm
Release the throttle lever and adjust the low idle speed set screw [B]
•
on the control plate to obtain the specified governed low idle speed.
Low Idle Speed (Governed idle rpm)
1550 rpm
High Idle Speed Adjustment
NOTE
High idle speed adjustment should be made after the idle speed
adjustment is performed.
CAUTION
Do not adjust high idle speed with the air cleaner removed.
Start and warm up the engine throughly.
•
Always keep your hands clear of the moving parts.
Move the throttle lever at a dash to the high idle position and match
•
the lever hole position with the panel hole by inserting 6 mm dia., pin
or bolt [A].
Loosen two M6 control panel mounting bolts [B] enough to move the
•
control panel assembly.
Carefully move the control panel assembly right side [C] up or down
•
to obtain the specified high idle speed.
High Idle Speed
3600 rpm
Tighten the M6 Mounting bolts.
•
1
Torque - Control Panel Mounting Bolts: 5.9 N
Remove the 6 mm dia., pin or bolt.
•
Check the idle speed, and readjust the idle speed if necessary.
•
m (0.60 kgf1m, 52 in1lb)
CAUTION
Be sure to make the idle and high idle speeds respectively
correspond to those of the equipment.
Periodic Maintenance Procedures
Fuel system Cleanliness Inspection
Gasoline is extremely flammable and can be explosive under
certain conditions. Turn the ignition switch OFF. Do not
smoke. Make sure the area is well-ventilated and free from
any source of flame or sparks; this includes any appliance
with a pilot light.
Remove the air cleaner (see Fuel System chapter).
•
Place a suitable container [A] under the float chamber mounting bolt
•
[B] on the carburetor.
Remove the float chamber to drain the carburetor and check to see
•
if water or dirt has accumulated in the carburetor.
Tighten the float chamber mounting bolt.
•
Torque - Float Chamber Mounting Bolt: 4.5 N1m (0.46 kgf
If any water or dirt is found, clean the carburetor (see Fuel System
•
chapter), and fuel tank, and check the fuel filter.
Fuel Pump Inspection
Check the vent hole [A] and filter [B] for plugging or clogging.
•
If vent hole and filter are plugged or clogged, remove the foreign
matter from them.
1
m, 40 in
PERIODIC MAINTENANCE 2-5
1
lb)
Fuel Flow Test:
Gasoline is extremely flammable and can be explosive under
certain conditions. Turn the ignition switch OFF. Do not
smoke. Make sure the area is well-ventilated and free from
any source of flame or sparks; this includes any appliance
with a pilot light.
Disconnect the fuel pump outlet nozzle from the tube.
•
Connect a suitable hose [A] to the outlet nozzle.
•
Run the lower end of the hose into a container.
•
Start the engine, Check the fuel flow.
•
If fuel flow is none or little, replace the fuel pump.
Check for clogged or damaged tubes and fuel fillter. Replace the
faulty parts.
Fuel Filter Inspection
Visually insect the fuel filter [A].
•
If the filter is clear with no signs of dirt or other contamination, it is
OK and need not be replaced.
If the filter is dark or looks dirty, replace with a new one. Also check
the rest of the fuel system for contamination.
2-6 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Air Element Removal
Push down the latches [A] and remove the air cleaner case [B].
•
Remove:
•
Paper Element [A]
Foam Element [B]
Air Element Installation
Install the element correctly on the air cleaner case.
•
Be sure the foam element is in-place in the air cleaner case.
•
Be sure the paper element is in-place in the air cleaner case.
•
Install the air cleaner case on the air cleaner body.
•
Be sure the latches of air cleaner case are in place in the air cleaner
•
body.
Be sure that the hollows [A] of the air cleaner case and projection [B]
•
of the air cleaner body are fitting.
Air Element Cleaning and Inspection
NOTE
In dusty areas, the elements should be cleaned more frequently
than the recommended intervals.
Because of the danger of highly flammable liquids, do not use
gasoline or a low flash-point solvent to clean the element.
Periodic Maintenance Procedures
Remove the foam element and the paper element.
•
Clean the foam element [A] in a bath of detergent and water, and let
•
the element air-dry throughly before installing it.
Clean the paper element [A] by tapping it gently on a flat surface to
•
remove dust. If the element is very dirty, replace it with a new one.
CAUTION
Do not use compressed air to clean the paper element. Do not
oil the paper or foam element.
Air Cleaner Housing (Case and Body) Inspection
Clean the housing with detergent and water and dry thoroughly.
•
Check the housing for deformation or other damage. The housing
•
must seal well and permit only filtered air to reach the carburetor.
If the housing is damaged, it must be replaced.
Check that no foreign material is obstructing the air passage.
•
Engine Top End
PERIODIC MAINTENANCE 2-7
Cylinder Head Cleaning and Inspection
Scrape the carbon deposits from the head and exhaust port with a
•
suitable tool [A].
To avoid gouging, use scrapers that are made of a material that will
•
not cause damage.
Clean the head in a bath of high flash-point solvent and dry it with
•
compressed air.
Clean the cylinder head in a well-ventilated area, and take care
that there are no sparks or flame anywhere near the working
area; this includes any appliance with a pilot light. Do not
use gasoline or a low flash-point solvent to clean the cylinder
head. A fire or explosion could result.
Straight edge [A] across the mating surface of the head at several
•
different points, and measure warp by inserting a thickness gauge
[B] between the straightedge and head.
If warp exceeds the service limit, repair the mating surface. Replace
the cylinder head if the mating surface is badly damaged.
Cylinder Head Warp
Service Limit: 0.03 mm (0.001 in.)
Check the cylinder head for cracks or other damage.
•
Cracks not visible to the eye may be detached by using a metal crack
•
detection system. (Visual color check: commonly found at automotive
parts tore.)
If a crack is present in the cylinder head, replace it.
•
Inspect the mating surface for burrs and nicks.
•
2-8 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Valve Clearance Inspection
NOTE
Valve clearance must be checked when the engine is cold (at room
temperature).
Remove the rocker cover (see Engine Top End chapter).
•
Place the piston at top dead center (TDC) of the compression stroke
•
turning the crankshaft clockwise facing the flywheel.
No.1 Cylinder:
The left projection [A] on the flywheel is faced with the right leg [B]
on the #1 ignition coil [C] as shown.
Check the intake and exhaust valvesare closed completely, if not, turn
the flywheel one turn (360
the right leg again.
No.2 Cylinder:
The left projection [A] on the flywheel is faced with the right leg [B]
on the #2 ignition coil [C] as shown. Follow No.1 Cylinder alignment.
) clockwise and face the left projection with
Then check the valve clearance.
•
Using a thickness gauge [A], measure the valve clearance beween
the rocker arm [B] and the valve stem end.
If the valve clearance is incorrect, adjust it.
Valve Clearance (when cold)
Intake, Exhaust 0.10 ~ 0.15 mm (0.004 ~ 0.006in.)
Valve Clearance Adjustment
Since valve repairs change the valve clearance, adjust the valve
•
clearance to the specification.
Assemble the cylinder head and install the cylinder head assembly
•
on the block (see Engine Top End chapter).
Turn the crankshaft to the proper direction until the piston is at TDC
•
of the compression stroke (described above).
Loosen the lock screws [A] and valve clearance adjusting nuts [B].
•
Insert a 0.10 mm (0.004 in.) thickness gauge [C] between the rocker
•
arm and valve stem, and tighten the adjusting nut until the thickness
gauge begins to bind between the rocker arm and valve stem end.
Use a sweeping motion with the thickness gauge while making this
adjustment.
Valve Clearance (when cold)
Intake, Exhaust 0.10 ~ 0.15 mm (0.004 ~ 0.006in.)
Holding the adjusting nut with a wrench, tighten the lock screw to the
•
specified torque.
Torque - Valve Clearance Lock Screws: 6.9 N1m (0.70 kgf1m, 61 in1lb)
Do not overtighten.
•
Remeasure any clearance that was adjusted. Readjust if necessary.
•
Periodic Maintenance Procedures
Valve Seat Inspection
Remove the valve (see Engine Top End chapter).
•
Inspect the valve seats for damage.
•
If the seats are warped or distorted beyond reconditioning, replace
the cylinder head.
Pitted or worn valve seats can be refaced. Lap the valves to the seats
•
after refacing.
Coat the valve seat with machinist’s dye.
•
Push the valve into the guide.
•
Rotate the valve against the seat with a lapping tool.
•
Pull the valve out, and check the seating pattern on the valve head.
•
It must be the correct width [A] and even all the way around.
NOTE
The valve stem and guide must be in good condition or this check
will not be valid.
If the valve seating pattern is not correct, repair the seat.
Valve Seating Surface Width (STD)
Inlet, Exhaust 0.6 ~ 0.9 mm (0.024 ~ 0.035 in.)
PERIODIC MAINTENANCE 2-9
Valve Seat Repair
Follow the manufacturer’s instructions for use of valve seat cutters.
•
Special Tools
Intake Valve:
Seat Cutter 45
Outside Cutter 32
Exhaust Valve:
Seat Cutter 45
Outside Cutter 32
Valve Seat Cutter HolderValve Seat Cutter Holder Bar: 57001-1128
If the manufacturer’s instructions are not available, use the following
procedure.
Seat Cutter Operating Cares:
1. This valve seat cutter is designed only for valve seat repair.
Therefore the cutter must not be used for other purposes.
2. Do not drop or hit the valve seat cutter, or the diamond particles
may fall off.
3. Do not fail to apply engine oil to the valve seat cutter before
grinding the seat surface. Also wash off ground particles sticking
to the cutter with washing oil.
6.0: 57001-1360
- 27.5 57001-1114
28.0 57001-1119
-
27.5 57001-1114
-
- 25.0 57001-1118
NOTE
Do not use a wire brush to remove the metal particles from the
cutter. It will take off the diamond particles.
4. Setting the valve seat cutter holder [A] in position, operate the
cutter [B] with one hand [C]. Do not apply too much force to the
diamond portion.
NOTE
Prior to grinding, apply oil to the cutter, and during the operation
wash off any ground particles sticking to the cutter with washing
oil.
5. After use wash the cutter with washing oil and apply a thin layer
of engine oil before storing.
2-10 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Marks Stamped on the Cutter:
The marks stamped on the back of the cutter represent the following.
1 Cutter number, selected from 1 to 12
30
37.5 Cutter diameter of cutter [B]
KS8B Manufactured lot number
Operating Procedures:
Clean the seat area carefully.
•
Recondition the valve seats with the valve seat cutters (45
•
lap the valves.
Check the seats for good contact all the way around with machinist’s
•
dye.
Measure the seat width [A]. If it is more than the STD width, the
•
seating surface should be refaced.
If the valve seating pattern is not correct, repair the seat.
•
Cutter angle [A]
,32) and
Coat the seat with machinist’s dye.
•
Fit a 45
•
Resurface the valve seat with a 45
material to produce a smooth and concentric seat.
Do not grind the seat too much. Overgrinding will reduce
valve clearance by sinking the valve into the head. If the valve
sinks too far into the head, it will be impossible to adjust the
clearance, and the cylinder head must be replaced. Do not
turn the cutter counterclockwise or drop it against the seat, or
it will be dulled.
Use a 32seat cutter [A] to narrow the seat width to the STD width.
•
Turn the seat cutter one turn at a time while pressing down very lightly.
Check the seat width after each turn.
The 32cutter removes material very quickly. Check the seat
width frequently to prevent over grinding.
Make a light pass with the 45cutter to remove any possible burrs at
•
the edge of the seat.
After resurfacing the seat, inspect for even valve seating.
•
Apply a machinist’s dye to the valve face, insert the valve, and snap it
closed against the seat several times. The valve surface should show
good contact all the way around. Be sure the valve seat is centered
on the valve face. The position of the valve in the seat is evident after
lapping the valve.
If the seat does not make proper contact, lap the valve into seat with
a vacuum cap tool.
cutter [A] to the holder and slide it into the valve guide.
CAUTION
CAUTION
Keep the seat width as close as possible to the STD width.
NOTE
cutter, removing only enough
Periodic Maintenance Procedures
Coat the face of valve sparingly with a fine lapping compound.
•
Use the vacuum cup tool [A], to grip top of the valve [B]. Rotate the
•
valve in a circular motion to lap the valve to the seat.
Lift the valve slightly from the seat every 8 to 10 strokes, continue
•
lapping operation until a uniform ring appears around entire surface
of the valve face.
When lapping is completed, wash all parts in solvent to remove
•
lapping compound. Dry the parts thoroughly.
Note the position of the lapping mark on the valve face. The lapping
•
mark should appear on or near the center of the valve face.
When the engine isassembled, be sure to adjust the valve clearances
•
(see Valve Clearance Adjustment).
Lubrication System
Oil Level Inspection
Place the engine on a level surface.
•
Remove the oil filler cap [A] and wipe its dipstick [B] with a clean
•
cloth.
Insert the dipstick into tube [C] without screwing it in, then check the
•
oil Level.
The oil level should be the operating range [D] (grid area) on the
•
dipstick.
If the oil level is “ADD” range [E], add enough engine oil to bring oil
level to the operating range.
PERIODIC MAINTENANCE 2-11
CAUTION
Do not add more oil above the operating range. Excess oil will
cause a smoking condition.
Use the same type and make of oil that is already in the engine.
NOTE
If the engine oil type and make are unknown, use any brand of the
specified oil to top up the level in preference to running the engine
with the oil level low. Then at your earliest convenience, change
the oil completely.
If the oil level is “FULL” range [F], drain the excess oil by loosening
the drain plug.
2-12 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Oil Change
Change the oil after first 8 hours of operation. Thereafter change oil
•
every 100 hours.
Start and warm up the engine so the oil will drain easily. Stop the
•
engine.
Place the engine on a level surface.
•
Place a suitable container under the engine.
•
Remove the drain plug [A] and drain the oil.
•
Be careful of hot oil when drained. It may be hot enough to
burn you severely.
Check the O-ring [B] at the drain plug for damage. Replace the O-
•
ring with a new one if it is damaged.
Install the drain plug with the O-ring and tighten it.
•
Torque - Oil Drain Plug : 6.9 N1m (0.70 kgf
Remove the oil filler cap and pour in the specified type and amount
•
of oil.
Engine Oil :
Type: SF, SG, SH or SJ Class
Viscosity: SAE40, SAE30, SAE10W-30/SAE10W-40, or
Capacity: [When filter is not removed]
SAE5W-20
1.5 L (1.6 US qt)
[When filter is removed]
1.7 L (1.8 US qt)
1
m, 61 in
1
lb)
NOTE
Some increase in oil consumption may be expected when a multi
grade engine oil (10W-30/10W-40, 5W-20) is used. Check the oil
level frequently.
Oil Filter Change
Using a strap wrench or oil filter wrench [A], remove the oil filter [B].
•
Special Tool - Oil Filter Wrench : 57001–1249
When unscrewing the oil filter, place a suitable container beneath the
oil drip tray to receive oil from the oil filter and oil passages in the
engine. Turn the filter counterclockwise to remove it.
Oil Filter Installation
Apply light film of engine oil to the seal [A].
•
Install new filter.
•
Turn the filter until the seal contacts mounting surface [B] of the
engine. Then turn the filter BY HAND (S) 3/4 turn more.
Run the engine at slow idle speed 2 minutes. Check for leaks around
•
the engine.
Stop the engine. Check the oil level (see Oil Level Inspection).
•
Periodic Maintenance Procedures
Electrical System
Spark Plug Cleaning and Inspection
Remove the spark plug (See Electrical System chapter).
•
If the plug is oily or has carbon build up on it, clean the plug using a
high flash-point solvent and a wire brush or other suitable tool.
If the spark plug electrodes are corroded or damaged, or if the
insulator is cracked, replace the plug. Use the standard spark plug
or its equivalent.
[A] Insulator
[B] Center Electrode
[C] Plug Gap
[D] Side Electrode
Spark Plug Gap Inspection
Measure the gap with a wire-type thickness gauge.
•
If the gap is incorrect, carefully bend the side electrode with a suitable
tool to obtain the correct gap.
Spark Plug Gap
Standard: 0.75 mm (0.030 in.)
PERIODIC MAINTENANCE 2-13
Fuel System
FUEL SYSTEM 3-1
Table of Contents
Exploded View...................................................................................................................................................................3-2
Specifications....................................................................................................................................................................3-4
Governor Link Mechanism................................................................................................................................................3-5
Control Panel Assembly Removal..............................................................................................................................3-5
Control Panel Assembly Installation...........................................................................................................................3-5
Governor Arm Removal..............................................................................................................................................3-5
Governor Arm Installation..........................................................................................................................................3-6
Governor Assembly Removal.....................................................................................................................................3-6
Governor Assembly Installation..................................................................................................................................3-6
Governor Assembly Inspection..................................................................................................................................3-7
Governor Shaft Removal............................................................................................................................................3-7
Governor Shaft Installation.........................................................................................................................................3-7
Carburetor.........................................................................................................................................................................3-8
Fuel and Air Flow.......................................................................................................................................................3-8
Low Idle Speed Adjustment.......................................................................................................................................3-9
High Idle Speed Adjustment......................................................................................................................................3-9
High Altitude Operation..............................................................................................................................................3-9
Main Jet Replacement...............................................................................................................................................3-9
Fuel system Cleanliness Inspection...........................................................................................................................3-9
Carburetor Removal.................................................................................................................................................3-10
Carburetor Installation..............................................................................................................................................3-10
Carburetor Disassembly/Assembly .........................................................................................................................3-11
Carburetor Cleaning.................................................................................................................................................3-12
Carburetor Inspection...............................................................................................................................................3-12
Intake Manifold................................................................................................................................................................3-14
Intake Manifold Removal..........................................................................................................................................3-14
Intake Manifold Installation.......................................................................................................................................3-14
Intake Manifold Inspection........................................................................................................................................3-15
Fuel Pump, Fuel Filter.....................................................................................................................................................3-16
Fuel Pump Inspection..............................................................................................................................................3-16
Fuel Filter Inspection................................................................................................................................................3-16
Air Cleaner......................................................................................................................................................................3-17
Element Removal ....................................................................................................................................................3-17
Element Installation..................................................................................................................................................3-17
Element Cleaning and Inspection............................................................................................................................3-17
Cleaner Body Removal ...........................................................................................................................................3-17
Cleaner Body Installation.........................................................................................................................................3-17
Housing (Case and Body) Inspection......................................................................................................................3-17
3
3-2 FUEL SYSTEM
Exploded View
1. Pilot Screw
2. Main Jet
T1: 0.7 N1m (0.07 kgf1m, 6 in1lb)
T2: 2.3 N
T3: 4.5 N
T4: 5.9 N
T5: 6.9 N
L: Apply non-permanent locking agent.
O: Apply engine oil.
S: Follow the specific tightening sequence.
1
m (0.23 kgf1m, 20 in1lb)
1
m (0.46 kgf1m, 40 in1lb)
1
m (0.60 kgf1m, 52 in1lb)
1
m (0.70 kgf1m, 61 in1lb)
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