Kawasaki FH451V User Manual

FH451V,FH500V,FH531V FH601V,FH641V,FH680V

FH721V

4–stroke air cooled v-twin gasoline engine

Service Manual

All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products & Machinery Group/Kawasaki Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously.

All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

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.

1. Crankcase Emission Control System 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.

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 Tableof Contents on the ﬁrst page of the chapter to ﬁnd the Spark Plug section.

Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.

This warning symbol identiﬁes special instruc-

tions or procedures which, if not correctly fol-

lowed, could result in personal injury, or loss of

life.

CAUTION

This caution symbol identiﬁes special instruc-

tions or procedures which, if not strictly ob-

served, could result in damage to or destruction

of equipment.

This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.

NOTE



This note symbol indicates points of particular interest for more efﬁcient and convenient operation.

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.

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.......................................................................................................................................................1-6

Periodic Maintenance Chart...............................................................................................................................................1-7

Torque and Locking Agent.................................................................................................................................................1-9

Special Tools....................................................................................................................................................................1-13

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-FH500V

Recoil Starter Model-FH500V

Cylinder Number Designation:

No.1 Cylinder is the left-hand cylinder viewed from the air cleaner. No.2 Cylinder is the right-hand cylinder viewed from the air cleaner.

Model Identiﬁcation

Electric Starter Model-FH680V

GENERAL INFORMATION 1-5

1-6 GENERAL INFORMATION

General Speciﬁcations

Items

Type of engine Cylinder layout 90 V-Twin Bore x Stroke 68 mm x 68 mm (2.68 in x 2.68 in) 75.2 mm x 76 mm (2.96 in x 2.99 in) Piston displacement 494 mL (30.1 cu. in) 675 mL (41.19 cu.in) Direction of rotation Counterclockwise facing the PTO shaft Compression release Automatic compression release Low idle speed 1550 rpm Fast idle speed 3600 rpm Ignition system Transistorized-ﬂy wheel magneto RFI Per Canada and U.S.A. requirements Starting system Electric starter and/or recoil starter Charging system 12 V - 13 amps with regulator Spark plug CHAMPION RCJ8Y NGK BPR4ES Carburetor Float type, ﬁxed main jet Float type, ﬁxed main jet, two barrel Fuel pump Diaphragm type pulse pump Air cleaner Dual stage element, dry type Governor Flyweight all speed governor Lubrication system Pressure feed by positive displacement pump

Oil ﬁlter Cartridge type full ﬂow ﬁlter Oil pressuer switch ON-OFF switch Oil capacity

(when engine is completely dry)

Cooling system Forced air cooling by fan Dimensions (L x W x H ) 425 mm x 359 mm x 324 mm 458 mm x 430 mm x 381mm

Electric starter model (16.7 in x 14.1 in x 12.8 in) (18.0 in x 16.9 in x 15.0 in)

Recoil starter model (16.7 in x 14.1 in x 14.2 in)

Dry weight

Electric starter model 34 kg (75 lb) 40.5 kg (89.3 lbs) 41.2 kg Recoil starter model 32 kg (71 lb)

FH451V, FH500V, FH531V FH601V, FH641V, FH680V FH721V

Forced air-cooled, vertical shaft, OHV, 4-stroke gasoline engine.

1.8 L (1.9 US-qt) 1.9 L

425 mm x 359 mm x 361 mm

(2.0 US-qt)

(90.8 lbs)

Speciﬁcations are subject to change without notice.

GENERAL INFORMATION 1-7

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.

FH451V, FH500V, FH531V

OPERATION INTERVAL

Daily First

Check or clean air intake screen Check and add engine oil Check for fuel and oil leakage Check for loose or lost nut and screw Check battery electrolyte level Clean air cleaner foam element (1) Clean air cleaner paper element (1) Clean dust and dirt from cylinder and

cylinder head ﬁns (1) Tighten nut and screws

Change engine oil Clean and re-gap spark plugs Change Oil ﬁlter Change air cleaner paper element (1)

Check and adjust vlave clearance Clean and lap valve seating surface Clean combustion chamber

(1): Service more frequently under dusty conditions.

: These items must be performed with the proper tools. See your authorized Kawasaki Engine Dealer for service,

unless you have the proper equipment and mechanical proﬁciency.

•

8hr.

• •

Every 25 hr.

•

Every 50 hr.

•

Every

100 hr.

•

Every

200 hr.

•

Every

300 hr.

•

1-8 GENERAL INFORMATION

Periodic Maintenance Chart

FH601V, FH641V, FH680V, FH721V

OPERATION

Daily First

cylinder head ﬁns (1) Tighten nut and screws

Change engine oil Clean and re-gap spark plugs Check and clean oil cooler ﬁns (FH721V

engines). Change Oil ﬁlter

Change air cleaner paper element (1)

Check and adjust vlave clearance Clean and lap valve seating surface Clean combustion chamber

(1): Service more frequently under dusty conditions.

: These items must be performed with the proper tools. See your authorized Kawasaki Engine Dealer for service,

unless you have the proper equipment and mechanical proﬁciency.

•

8hr.

• •

Every 25 hr.

•

INTERVAL

Every 50 hr.

Every

100 hr.

•

Every

200 hr.

•

Every

300 hr.

•

GENERAL INFORMATION 1-9

Torque and Locking Agent

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

locking agent or liquid gasket.

Letters used in the "Remarks" column mean:

L:Apply a non-permanent locking agent to the threads. M:Apply a molybdenum disulﬁde lubricant (grease or oil) to the threads, seated surface, or washer. O:Apply an oil to the threads, seated surface, or washer.

S:Tighten the fasteners following the speciﬁed sequence.

SS : Apply silicone sealant.

FH451V, FH500V, FH531V

Fastener

Fuel System:

Choke Valve Screw 0.7 0.07 6in1lb

Throttle Valve Screws 1.0 0.10 9in

Pilot Jet 1.7 0.17 15 in

Main Jet 0.7 0.07 6in1lb

Main Air Jet 0.7 0.07 6in

Main Nozzle 2.0 0.20 17 in1lb

Pilot Air Jet 0.7 0.07 6in

Drain Screw (Carburetor) 1.3 0.13 11 in

Earth Lead Screw 3.4 0.35 30 in

(Carburetor Side)

Fuel Shut Off Solenoid Valve 6.9 0.70 61 in

(Carburetor)

Float Chamber Mounting Screw 8.8 0.90 78 in-lb

(Carburetor) Governor Arm Clamp Nut 7.8 0.8 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 5.9 0.6 52 in Cleaner Body Mounting Screws 3.4 0.35 30 in Control Panel Mounting Bolts 5.9 0.6 52 in1lb

Cooling System:

Engine-shoroud Bolt (M8) 15 1.5 11 Engine-shoroud Bolts (M6) 5.9 0.6 52 in1lb Plug Bolt (Engine-shroud) 5.9 0.6 52 in1lb Plug Screw (Engine-shroud) 3.4 0.35 30 in

Engine Top End

Cylinder Head Bolts 25 2.6 19.0 =S Valve Clearance Lock Screws 6.9 0.70 61 in1lb 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 0.6 52 in1lb Exhaust Pipe Flange Nuts 15 1.5 11 Spark Plugs 22 2.2 16

FH451V, FH500V, FH531V

Torque

kg1m ft1lb

Remarks

1-10 GENERAL INFORMATION

Torque and Locking Agent

Fastener

Lubrication System:

Engine Drian Plugs (Plastic) Engine Drain Plug (Metal) 20 2.0 14.5 Engine Drain Plug Joint (Plastic) 17 1.7 12.0 Engine Drain Plug Joint (Metal) 39 4.0 29 Oil Pressure Switch Oil Passage Plug 3.9 0.40 35 in1lb Oil Pump Cover Plate Mounting Bolts 5.9 0.6 52 in1lb Oil Filter in the text

Camshaft/Crankshaft:

Crankcase Cover Bolts 25 2.6 19.0 =S Breather Chamber Cover Bolts 5.9 0.6 52 in

Electrical System:

Starter Coil Screws 3.4 0.35 30 in1lb Flywheel Bolt 56 5.7 41 Fan Housing Bolts 5.9 0.6 52 in1lb Screen Bolts 5.9 0.6 52 in1lb Regulator Screws 3.4 0.35 30 in Ignition Coil Bolts (Studs) 7.8 0.8 69 in Ignition Coil Bolts (Bolts) 5.9 0.6 52 in1lb Starter Motor Mounting Bolts 15 1.5 11 Recoil Starter Mounting Nuts 5.9 0.6 52 in1lb Recoil Starter Retainier Screw 7.8 0.8 69 in1lb Spark Plugs 15 1.5 11.0

FH451V, FH500V, FH531V

Torque

N1m kg1m ft1lb

6.9 0.70 61 in1lb

9.8 1.0 87 in

Remarks

=SS

Torque and Locking Agent

FH601V, FH641V, FH680V, FH721V

GENERAL INFORMATION 1-11

Fasteners

Fuel System:

Choke Valve Screw 1.0 0.10 8.9 in Throttle Valve Screws Pilot Jet – – – Main Jet – – Plug, Main Jet 19 1.9 14 Main Nozzle – – – Main Air Jet – – – Pilot Air Jet – – – Drain Screw(Carburetor) 2.0 0.2 18 in1lb Earth lead screw – – –

(Carburetor Side) Fuel Shut Off Solenoid Valve (Carburetor) 20 2.0 15

Float Chamber Mounting 3.9 0.4 35 in1lb Screw(Carburetor) Governor Arm Clamp Nut 7.8 0.8 69 in Governor Shaft Plate Screws 2.0 0.2 18 in Intake Pipe Mounting Bolts and Nuts 5.9 0.6 52 in1lb

Intake Manifold Mounting Bolts 5.9 0.6 52 in1lb Cleaner Body Mounting Screws – – – Control Panel Mounting Bolts 5.9 0.6 52 in

Cooling System:

Engine-shroud Bolt (M8) 15 1.5 11 Engine-shroud Bolts (M6) 5.9 0.6 52 in Plug Bolt (Engine-shroud) – – – Plug Screw (Engine-shroud) 3.4 0.35 30 in

Engine Top End:

Cylinder Head Bolts 25 2.6 19 =S Valve Clearance Lock Screws 6.9 0.7 61 in Connecting Rod Big End 21 2.1 15 =O Cap Bolts Rocker Arm Bolts 28 2.8 20 Rocker Cover Mounting Bolts 5.9 0.6 52 in-lb Exhaust Pipe Flange Nuts 15 1.5 11 Spark Plugs 22 2.2 16

FH601V, FH641V, FH680V, FH721V

Torque

1.0 0.10 8.9 in

kg1m ft1lb

Remarks

=L =L

1-12 GENERAL INFORMATION

Torque and Locking Agent

Fastener

Lubrication System:

Engine Drian Plugs (Plastic) Engine Drain Plug (Metal) 20 2.0 14.5 Engine Drain Plug Joint (Plastic) 17 1.7 12 Engine Drain Plug Joint (Metal) 39 4.0 29 Oil Pressure Switch Oil Passage Plug 3.9 0.40 35 in1lb Oil Pump Cover Plate Mounting Bolts 5.9 0.6 52 in1lb Oil Filter in the text Oil Cooler Mounting Joint 44 4.5 33

Camshaft/Crankshaft:

Crankcase Cover Bolts Breather Chamber Cover Bolts 5.9 0.6 52 in1lb

Electrical System:

Starter Coil Screws 3.4 0.35 30 in Flywheel Bolt 56 5.7 41 Fan Housing Bolts 5.9 0.6 52 in1lb Screen Bolts 5.9 0.6 52 in Regulator Screws 3.4 0.35 30 in Ignition Coil Bolts (Studs) 7.8 0.8 69 in1lb Ignition Coil Bolts (Bolts) 5.9 0.6 52 in Starter Motor Mounting Bolts 15 1.5 11 Recoil Starter Mounting Nuts – – – Recoil Starter Retainier Screw – – – Spark Plugs 22 2.2 16

FH601V, FH641V, FH680V, FH721V

Torque

N1m kg1m ft1lb

6.9 0.7 61 in1lb

9.8 1.0 87 in

25 2.6 19.0 =S

Remarks

=SS

S:Tighten the fasteners following the speciﬁed sequence.

SS : Apply silicone sealant.

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a speciﬁc torque value. All of the values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners

Threads dia

Torque

(mm) N1m kg1m ft1lb

4 2.0 0.2 17 in1lb 5 3.4 0.35 30 in1lb 6 5.9 0.6 52 in-lb 8 15 1.5 11

Special Tools

GENERAL INFORMATION 1-13

Compression Gauge: 57001–221

Piston Ring Pliers: 57001–115

Piston Ring Compression Grip: 57001–1095

Valve Seat Cutter Holder Ø6: 57001–1360

Valve Seat Cutter, 45- Ø35.0: 57001–1116

Valve Seat Cutter, 30- Ø 33.0: 57001–1199

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

Valve Seat Cutter Holder Bar: 57001–1128

Compression Gauge Adapter M14 x 1.25: 57001–1159

Valve Seat Cutter, 30- Ø 30.0: 57001–1120

1-14 GENERAL INFORMATION

Special Tools

Oil Filter Wrench : 57001–1249

Hand Tester: 57001–1394

Kawasaki Bond (Silicone Sealant) : 56019–120

FUEL SYSTEM 2-1

Fuel System

Table of Contents

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

Speciﬁcations...............................................................2-8

Governor Link Mechanism..........................................2-9

Control Panel Assembly Removal........................2-9

Control Panel Assembly Installation.....................2-9

Governor Arm Removal........................................2-9

Governor Arm Installation...................................2-10

Governor Assembly Removal.............................2-10

Governor Assembly Installation..........................2-10

Governor Assembly Inspection...........................2-11

Governor Shaft Removal....................................2-11

Governor Shaft Installation.................................2-11

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

Fuel and Air Flow...............................................2-12

Fuel Shut Off Solenoid Valve (Electric Starter

Model).................................................................2-13

Low Idle Speed Adjustment................................2-13

High Idle Speed Adjustment...............................2-13

High Altitude Operation......................................2-14

Main Jet Replacement........................................2-14

Fuel system Cleanliness Inspection...................2-15

Carburetor Removal............................................2-16

Carburetor Installation........................................2-16

Carburetor Disassembly/Assembly - FH451V, 500V,

531V...................................................................2-17

Carburetor Disassembly/Assembly-FH601V, 641V,

680V, 721V..........................................................2-18

Carburetor Cleaning...........................................2-19

Carburetor Inspection.........................................2-20

Fuel Shut-Off Solenoid Valve Test (ElectricStarter

Model).................................................................2-21

Intake Manifold..........................................................2-22

Intake Manifold Removal....................................2-22

Intake Manifold Installation.................................2-22

Intake Manifold Inspection..................................2-23

Fuel Pump, Fuel Filter...............................................2-24

Fuel Pump Inspection.........................................2-24

Fuel Filter Inspection..........................................2-24

Air Cleaner.................................................................2-25

Element Removal - FH451V, 500V, 531V..........2-25

Element Removal - FH601V, 641V, 680V, 721V 2-25

Element Installation............................................2-25

Element Cleaning and Inspection - FH451V, 500V,

531V...................................................................2-25

Element Cleaning and Inspection - FH601V, 641V,

680V, 721V ........................................................2-26

Cleaner Body Removal - FH451V, 500V, 531V..2-26 Cleaner Body Removal - FH601V, FH641V, FH680V,

FH721V .............................................................2-27

Cleaner Body Installation - FH451V, 500V, 531V2-27 Cleaner Body Installation - FH601V, 641V, 680V,

721V ..................................................................2-27

Housing (Case and Body) Inspection.................2-28

2-2 FUEL SYSTEM

Exploded View

[FH451V, FH500V, FH531V]

Exploded View

[FH451V, FH500V, FH531V]

1. Pilot Screw

2. Pilot Air Jet

3. Main Air Jet

4. Main Jet

5. Pilot Jet

6. Solenoid Valve

FUEL SYSTEM 2-3

T1: 0.7 N T2: 1.0 N T3: 1.3 N T4: 1.7 N T5: 2.0 N T6: 3.4 N T7: 3.9 N T8: 6.9 N T9: 7.8 N

T10: 8.8 N

m (0.07 kg

m (0.10 kg

m (0.13 kg

m (0.17 kg

m (0.20 kg

m (0.35 kg

m (0.40 kg

m (0.70 kg

m (0.80 kg

m (0.90 kg

m, 6 in

m, 9 in

m, 11 in

m, 15 in

m, 17 in

m, 30 in

m, 35 in

m, 61 in

m, 69 in

m, 78 in

lb)

2-4 FUEL SYSTEM

Exploded View

[FH601V, FH641V, FH680V, FH721V]

Exploded View

[FH601V, FH641V, FH680V, FH721V]

1. Pilot Screw

2. Pilot Air Jet

3. Main Air Jet

4. Main Jet

5. Pilot Jet

6. Solenoid Valve

FUEL SYSTEM 2-5

T1: 1.0 N T2: 3.9 N T3: 2.0 N T4: 19 N T5: 20 N T6: 6.9 N

m (0.10 kg

m (0.40 kg

m (0.20 kg

m (1.9 kg

m (2.0 kg

m (0.70 kg

m, 9 in

m, 35 in

m, 18 in

m, 14 ft

m, 15 ft

m, 61 in

lb)

2-6 FUEL SYSTEM

Exploded View

[FH451V, FH500V, FH531V]

T5: 2.0 N T8: 5.9 N T9: 7.8 N

[FH601V, FH641V, FH680V, FH721V]

T5: 2.0 N T8: 5.9 N T9: 7.8 N

O: Apply engine oil.

m (0.20 kg

m (0.60 kg1m , 52 in

m (0.80 kg1m , 69 in

m (0.20 kg

m (0.60 kg

m (0.80 kg1m , 69 in

m , 17 in

m , 52 in

lb)

FUEL SYSTEM 2-7

2-8 FUEL SYSTEM

Speciﬁcations

Standard

Item

Caburetors Speciﬁcations:

Make/ type MIKUNI B24T1 Throttle bore diameter 24 mm (0.94 in.) Venturi diameter 16 mm (0.63 in.) 18 mm (0.71 in.) 21 mm (0.83 in.) Main Jet (MJ) #125 #116.3 L: #136, R: #140 Pilot jet (PJ) #48.8 #43.8 L: #46, R: #44 Main air jet (MAJ) ø1.7 ø1.4 Pilot air jet (PAJ) ø1.2 ø0.8

Pilot air screw turns out (PS) 2 1/4 1 3/8 L: 2 1/4, R: 1 1/4

(Idle mixture screw turns out)

Float level Float parallel to carburetor body

Idle Speed: (1)

Low idle speed 1550 r/min (rpm) High idle speed 3600 r/min (rpm)

Air Cleaner:

Type Dual stage ﬁltration system Pre-cleaner Foam element Second-stage cleaner Paper element

Fuel:

Fuel requirement Unleaded regular grade gasoline

Fuel Pump:

Type Pulse-diaphragm pump

Governor:

Type Flyweight all speed governor

FH451V, FH500V,

FH531V

FH601V, FH641V, FH680V,

Nikki 621266 26 mm (1.02 in.)



1.7



1.1

FH721V

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

Governor Link Mechanism

Control Panel Assembly Removal

Remove:

•

Air Cleaner (see Cleaner Body Removal) Air Cleaner Mount Bracket Bolts [A] Air Cleaner Mount Bracket [B] Earth Lead (Starter Model) Control Panel Mounting Bolts [C]

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

•

spring [B] end loop at the panel bracket. Clear the choke link rod lower end [C] from the choke lever.

•

FUEL SYSTEM 2-9

Control Panel Assembly Installation

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

•

choke lever [A] and engine speed control lever [B] move smoothly in all directions. If any part is worn or damaged, replace the control panel assembly. After installation, adjust the low idle speeds and high idle speeds

•

to the speciﬁcations (see Low Idle Speed and High Idle Speed adjustment).

Governor Arm Removal

Remove:

•

Control Panel Assembly Loosen the clamp nut [A] and take off the governor arm [B].

•

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

•

throttle link rod lower end [D].

2-10 FUEL SYSTEM

Governor Link Mechanism

Governor Arm Installation

Install the governor arm [A] onto the governor shaft [B] temporarily.

•

Be sure the link spring [C] around the throttle link rod [D] is inplace

•

and that it pulls the governor arm and throttle lever [E] each other.

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

•

governor shaft.

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

•

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

Turn the governor shaft counterclockwise, fully turn the shaft to end

•

of its travel.

Tighten the clamp nut.

•

Torque - Governor Arm Clamp Nut: 7.8 N1m (0.80 kg

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

•

mately 7 mm (0.3 in) [H] as shown.

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

•

the governor spring.

m, 69 in1lb)

Governor Assembly Removal

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

•

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

•

Upside down the engine.

•

Remove the camshaft [A].

•

Remove:

•

Washer [A]

Snap Ring [B]

Sleeve [C]

Governor Plate [D]

Snap Ring [B]

Steel balls [E]

Ball Guide [F]

Ball Plate [G]

Governor Assembly Installation

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

•

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

•

governor plate operate freely.

Governor Link Mechanism

Governor Assembly Inspection



Visually check all governor parts for wear and damage. If any parts are worm or damaged, replace them.

Governor Shaft Removal

Split the crankcase (see Camshaft/Crankcase chapter).

•

Unscrewthe governor shaft plate screws [A], and pull out the governor

•

shaft [B] outside.

NOTE



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

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

•

been damaged.

The oil seal [A] must be assembled with seal lip towards inside of the

•

engine. Press in the oil seal 0

•

crankcase surface [C].

1.0 mm (0.04 in.) [B] ﬂush or below the

FUEL SYSTEM 2-11

Governor Shaft Installation

Apply engine oil to the governor shaft.

•

Insert the governor shaft into the crankcase.

•

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

•

Torque - Governor Shaft Plate Screws: 2.0 N1m (0.20 kg1m, 17 in1lb)

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

•

NOTE



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

2-12 FUEL SYSTEM

Carburetor

Fuel and Air Flow

The main system of the carburetor consists of the main jet [A], Valve seat [B] main nozzle [C], and the main air passage [D] (main air jet [E]). The main system meters fuel to the engine during moderate to heavy load conditions. Fuel ﬂows through the main jet and into the main nozzle, where it is joined by air from the main air passage (main air jet). The resulting mixture ﬂows out the end of the main nozzle into the carburetor bore, where it is atomized by the high speed air ﬂow, and carried into the engine.

The pilot system includes the pilot jet [F], pilot screw [G] (Idle mixture screw), pilot air jet [H], pilot outlet [I], and the bypass holes [J]. The pilot system meters the fuel/air mixture while the engine is idling and running under a light load. Under these conditions there is very little air ﬂow through the carburetor bore; so little that it is not enough to draw fuel through the main system of the carburetor and atomize it. Instead, the fuel is drawn through the pilot system, since the nearly closed throttle valve [K] causes high speed air ﬂow past the pilot outlet and bypass holes (even at low engine speed).

Fuel ﬂow in the pilot system is metered by the pilot jet. Air for better atomization is admitted via the pilot air jet in the mouthof the carburetor. The fuel/air mixture passes into the bore of the carburetor side stream of the throttle valve through the bypass holes and pilot outlet. While the throttle valve is almost closed, it covers the small bypass holes opening into the bore from the pilot system. As the throttle valve begins to open, it uncovers the bypass holes, allowing more fuel/air mixture to ﬂow. The extra ﬂow is needed because the engine starts to run faster as the throttle is opened. The pilot screw controls the amount of fuel/air mixture allowed through the pilot outlet, but does not meter the bypass holes. A moderate amount of air comes in around the throttle valve at an idle, so adjusting the pilot screw changes the fuel/air ratio. Turning the pilot screw (Idle mixture screw) out (Counterclockwise) enrichens the mixture; turning it in (clockwise) leans the mixture.

Main Fuel Flow Pilot Fuel Flow ⇒

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